Factory Workshop Manual
Make
Chevrolet
Model
Colorado 2wd
Engine and year
V8-5.3L (2009)
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This manual was submitted by
Anonymous
Date
1st January 2018
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Accessory Relay > Component Information > Locations
Accessory Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Diagrams
Alarm Module: Diagrams
Component Connector End Views
Theft Deterrent Module (TDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component Views
Central Control Module: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Below the I/P Components - 1 of 2
1 - Vehicle Communication Interface Module (VCIM) X1 (UE1) 2 - Vehicle Communication Interface
Module (VCIM) X2 (UE1) 3 - Vehicle Communication Interface Module (VCIM) (UE1) 4 - I/P
Courtesy Lamp - Right 5 - I/P Courtesy Lamp - Left 6 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component Views >
Page 14
Central Control Module: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component Views >
Page 15
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 >
Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 >
Campaign - Unwanted Repeat Calls to OnStar(R) > Page 24
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 >
Campaign - Unwanted Repeat Calls to OnStar(R) > Page 25
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 >
Campaign - Unwanted Repeat Calls to OnStar(R) > Page 26
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: >
08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Communications Control Module: Customer Interest OnStar(R) - Generation 8.0L Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: >
08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 32
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Communications Control Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L
Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page
38
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 43
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 44
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
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for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 45
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
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for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 50
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using
OnStar(R)
Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute
Enough When Using OnStar(R)
TECHNICAL
Bulletin No.: 10-08-46-001
Date: January 27, 2010
Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are
Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R)
Customer Service)
Models:
2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009
Saab 9-7X All Equipped with OnStar(R) (RPO UE1)
Condition
Some customers may comment that when the radio is on, it does not mute enough when the
OnStar(R) Turn-by-Turn Navigation directions are announced.
Cause
This condition may be caused by the customer improperly setting the radio volume high enough
when the Turn-by-Turn Navigation messages are played.
The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on
during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can
still be heard at a very low volume. Previous model years initiated a "hard mute" during this
function which completely muted the radio audio.
Correction
Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation
direction announcements. You can control the message volume using the radio volume control,
only when the Turn-by-Turn navigation messages are playing.
Some customers that were accustomed to previous model vehicles with the "hard mute" feature
may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the
OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained
Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the
hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then
create a case number. Advise the customer that the vehicle update should be completed Over the
Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the
customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise
them to press the Blue OnStar(R) Button and ask for Customer Care to check status.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
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Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using
OnStar(R) > Page 55
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Communications Control Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L
Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
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Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 61
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
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Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 66
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using
OnStar(R)
Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute
Enough When Using OnStar(R)
TECHNICAL
Bulletin No.: 10-08-46-001
Date: January 27, 2010
Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are
Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R)
Customer Service)
Models:
2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009
Saab 9-7X All Equipped with OnStar(R) (RPO UE1)
Condition
Some customers may comment that when the radio is on, it does not mute enough when the
OnStar(R) Turn-by-Turn Navigation directions are announced.
Cause
This condition may be caused by the customer improperly setting the radio volume high enough
when the Turn-by-Turn Navigation messages are played.
The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on
during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can
still be heard at a very low volume. Previous model years initiated a "hard mute" during this
function which completely muted the radio audio.
Correction
Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation
direction announcements. You can control the message volume using the radio volume control,
only when the Turn-by-Turn navigation messages are playing.
Some customers that were accustomed to previous model vehicles with the "hard mute" feature
may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the
OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained
Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the
hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then
create a case number. Advise the customer that the vehicle update should be completed Over the
Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the
customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise
them to press the Blue OnStar(R) Button and ask for Customer Care to check status.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
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Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using
OnStar(R) > Page 71
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
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Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 77
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
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Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 78
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 79
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
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Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 84
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using
OnStar(R) > Page 89
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Page 90
Communications Control Module: Diagrams
Component Connector End Views
Vehicle Communications Interface Module (VCIM) X1
Vehicle Communications Interface Module (VCIM) X2
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Communications Control Module > Component Information > Technical Service Bulletins > Page 91
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Communications Control Module > Component Information > Technical Service Bulletins > Page 92
Communications Control Module: Service and Repair
Communication Interface Module Replacement
Removal Procedure
Note: The vehicle communication interface module (VCIM) has a specific set of unique numbers
that tie the module to each vehicle. These numbers, the 10-digit station identification (STID) and
the 11-digit electronic serial number (ESN), are used by the National Cellular Network and
OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle
identification number of the vehicle, you must never exchange these parts with those of another
vehicle.
1. Ensure the ignition switch is in the OFF position.
2. Remove the service panel located on the right side of the instrument panel (I/P).
3. Disconnect the VCIM electrical connectors as necessary.
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Communications Control Module > Component Information > Technical Service Bulletins > Page 93
4. Remove the screw retaining the VCIM to the bracket.
5. Release the tab (1) on the bracket.
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Communications Control Module > Component Information > Technical Service Bulletins > Page 94
6. Remove the VCIM from the bracket.
7. Remove the VCIM from the vehicle.
Installation Procedure
1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the
labels on the new module.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Communications Control Module > Component Information > Technical Service Bulletins > Page 95
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the VCIM to the bracket ensuring the retaining tab (1) is fully seated.
Tighten the screw fully driven , seated and not stripped.
3. Connect the VCIM electrical connectors as necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Communications Control Module > Component Information > Technical Service Bulletins > Page 96
4. Install the service panel.
Note: After replacing the VCIM, you must reconfigure the OnStar(R) system. Failure to reconfigure
the system will result in an additional customer visit for repair. In addition, pressing and holding the
white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will
cause a DTC to set.
5. Reconfigure the OnStar(R) system. Refer to Control Module References (See: Testing and
Inspection/Programming and Relearning). 6. When replacing the communication interface module
be sure to transfer Bluetooth Antenna, if equipped.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C
> Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C
> Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 105
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number
Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 111
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Emergency Contact Module: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set
Fuel Tank Pressure Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's
P0451/P0454 Set
TECHNICAL
Bulletin No.: 10-06-04-001C
Date: December 08, 2010
Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure
Sensor Cover)
Models:
2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to
November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to
November 4, 2009) 2009-2010 Pontiac G5
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System).
Condition
Some customers may comment on a check engine light. Upon further investigation, a technician
may find one of the above DTCs.
Cause
This condition may be caused by normal water accumulation or condensation blocking the air
reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If
the signal varies during an Engine Off Natural Vacuum test, a false DTC could set.
Correction
Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI
diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield,
P/N 20893611. Clear the DTCs.
Chevrolet Colorado, Silverado and GMC Canyon, Sierra
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable
adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank
straps. 5. Lower the fuel tank halfway.
6. Locate the fuel tank pressure sensor (1).
7. Install the fuel tank pressure sensor cover, GM P/N 20893611.
Chevrolet Cobalt and Pontiac G5
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
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Emergency Contact Module: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page 125
2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
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Emergency Contact Module: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page 131
2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global
Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global
Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Global Positioning System Module: Customer Interest OnStar(R) - Generation 8.0L Software
Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
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Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global
Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 140
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global
Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Global Positioning System Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L
Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global
Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page
146
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: >
08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Navigation Module: Customer Interest OnStar(R) - Generation 8.0L Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: >
08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 155
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation
Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Navigation Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation
Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 161
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D >
Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules
Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D >
Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 170
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D >
Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 171
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D >
Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 172
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules
Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control
Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 178
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 179
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 180
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Locations
Seat Heater Control Module: Locations
Passenger Compartment/Roof Component Views
Under the Driver Seat Components
1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1)
5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver
Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver
Under the Passenger Seat Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Locations > Page 185
1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor
(SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger
(KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1)
7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Locations > Page 186
Seat Heater Control Module: Service and Repair
Front Seat Heater Control Module Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 192
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 193
Electronic Brake Control Module: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 194
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 195
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 196
Electronic Brake Control Module: Diagrams
Component Connector End Views
Electronic Brake Control Module (EBCM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 197
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 198
Electronic Brake Control Module: Service and Repair
Electronic Brake Control Module Replacement
Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction
Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes
and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint
and Electrical Components Caution).
1. Turn the ignition switch to the OFF position. 2. Remove the brake pressure modulator valve
(BPMV). Refer to Brake Pressure Modulator Valve Replacement (See: Brakes and Traction
Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock
Brakes/Service and Repair).
3. Remove the electronic brake control module (EBCM) bolts (1).
Discard the bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 199
4. Carefully separate the EBCM (1) from the BPMV. 5. Remove the 12 EBCM to BPMV seals (2).
Installation Procedure
1. Carefully install the EBCM (1) and the 12 seals (2) to the BPMV.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: Do not reuse the EBCM bolts. Install new bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 200
2. Install new EBCM bolts (1) and tighten to 2 Nm (18 lb in). 3. Install the EBCM/BPMV assembly to
the vehicle. Refer to Brake Pressure Modulator Valve Replacement (See: Brakes and Traction
Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock
Brakes/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations
Compressor Clutch Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 205
Compressor Clutch Relay: Service and Repair
Compressor Relay Replacement
Removal Procedure
1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay
(2).
Installation Procedure
1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component
Information > Locations
System Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay
> Component Information > Locations
Fog/Driving Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations
Headlamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations
High Beam Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay >
Component Information > Locations
Horn Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay >
Component Information > Locations
Low Beam Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Parking Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module
> Component Information > Service and Repair
Trailer Lighting Module: Service and Repair
Trailer Lamp Control Module Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Accessory
Relay > Component Information > Locations
Accessory Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component
Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place.
3. Remove any connector position assurance (CPA) devices or secondary locks.
Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners
or tape.
4. Separate the relay (1) from the wire harness connector (2).
Installation Procedure
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page
239
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Special Tools
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification
Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID) to
locate the electrical center where the relay exists.
Note: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
3. Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
4. Remove the relay (2) from the electrical center.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page
240
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Customer Interest for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start
Up
Body Control Module: Customer Interest Body Controls - Security Lamp ON After Start Up
TECHNICAL
Bulletin No.: 09-08-56-001
Date: March 12, 2009
Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs
(Reprogram BCM)
Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T
Note
The information contained in this bulletin applies to vehicles located in the U.S. only.
Condition
Some customers may comment that the Security Light remains illuminated after the vehicle has
started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and
Engine Control Module (ECM).
Cause
This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run"
and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM
sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the
"Crank" mode to turn the light off.
Correction
Important Do Not replace the ignition switch for this concern.
1. Verify the customer concern.
2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI.
3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the
latest software available on TIS2WEB. Refer to the
Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with
the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON
After Start Up
Body Control Module: All Technical Service Bulletins Body Controls - Security Lamp ON After Start
Up
TECHNICAL
Bulletin No.: 09-08-56-001
Date: March 12, 2009
Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs
(Reprogram BCM)
Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T
Note
The information contained in this bulletin applies to vehicles located in the U.S. only.
Condition
Some customers may comment that the Security Light remains illuminated after the vehicle has
started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and
Engine Control Module (ECM).
Cause
This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run"
and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM
sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the
"Crank" mode to turn the light off.
Correction
Important Do Not replace the ignition switch for this concern.
1. Verify the customer concern.
2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI.
3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the
latest software available on TIS2WEB. Refer to the
Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with
the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views
Body Control Module: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views > Page 258
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views > Page 259
15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views > Page 260
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210
(A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control
Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to
Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views > Page 261
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views > Page 262
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views > Page 263
Body Control Module: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Right Kick Panel Components
1 - Body Harness 2 - Instrument Panel Harness 3 - Body Control Module (BCM) 4 - X201 5 - Body
Control Module (BCM) X2 6 - Body Control Module (BCM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 264
Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 265
Body Control Module (BCM) X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 266
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 267
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 268
Body Control Module: Service and Repair
Body Control Module Replacement
Removal Procedure
Important:
* The ignition switch should be in the OFF position when connecting or disconnecting the
connectors to the body control module (BCM).
* Always disconnect the black body wiring harness connector FIRST and the gray instrument panel
(I/P) wiring harness connector LAST.
* Always connect the black body wiring harness connector FIRST and the gray I/P wiring harness
LAST.
* Do not open the BCM housing. The module does not have any serviceable components. The
module may be replaced only as an assembly.
1. Ensure the ignition switch is in the OFF position. 2. Remove the right front hinge pillar trim panel.
Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
3. Disconnect the body wiring harness electrical connector (1) from the BCM.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 269
4. Disconnect the I/P wiring harness electrical connector (1) from the BCM.
5. Release the fastener retaining the body wiring harness electrical connector to the BCM.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 270
6. Remove the 2 fasteners retaining the BCM to the hinge pillar. 7. Remove the BCM from the
hinge pillar by unlocking the integral tab. 8. Remove the BCM from the vehicle.
Installation Procedure
1. Position the BCM to the vehicle. 2. Attach the BCM to the hinge pillar with the integral tab. 3.
Install the 2 fasteners retaining the BCM to the hinge pillar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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4. Install the fastener retaining the body wiring harness electrical connector to the BCM.
5. Connect the body wiring harness electrical connector (1) to the BCM.
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6. Connect the I/P wiring harness electrical connector (1) to the BCM. 7. Install the right front hinge
pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and
Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
8. If installing a replacement BCM, program the BCM. Refer to Control Module References (See:
Testing and Inspection/Programming and
Relearning).
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage
Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory
Usage
INFORMATION
Bulletin No.: 04-06-04-054B
Date: November 18, 2010
Subject: Info - Non-GM Parts and Accessories (Aftermarket)
Models:
2011 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed
Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate
Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System).
The recent rise and expansion of companies selling non-GM parts and accessories has made it
necessary to issue this reminder to dealers regarding GM's policy on the use and installation of
these aftermarket components.
When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to
use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs,
special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the
same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty
repairs, special policy repairs or any repairs paid for by GM.
During a warranty repair, if a GM original equipment part is not available through GM Customer
Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources,
the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order
the circumstances surrounding why non-GM parts were used. The dealer must give customers
written notice, prior to the sale or service, that such parts or accessories are not marketed or
warranted by General Motors.
It should also be noted that dealers modifying new vehicles and installing equipment, parts and
accessories obtained from sources not authorized by GM are responsible for complying with the
National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed
by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design
characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully
understand that non-GM approved parts may not have been validated, tested or certified for use.
This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part
failure occurs as the result of the installation or use of a non-GM approved part, the warranty will
not be honored.
A good example of non-authorized modification of vehicles is the result of an ever increasing
supply of aftermarket devices available to the customer, which claim to increase the horsepower
and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to
one or more of the following modifications:
- Propane injection
- Nitrous oxide injection
- Additional modules (black boxes) that connect to the vehicle wiring systems
- Revised engine calibrations downloaded for the engine control module
- Calibration modules which connect to the vehicle diagnostic connector
- Modification to the engine turbocharger waste gate
Although the installation of these devices, or modification of vehicle components, can increase
engine horsepower and torque, they may also negatively affect the engine emissions, reliability
and/or durability. In addition, other powertrain components, such as transmissions, universal joints,
drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the
installation of these devices.
General Motors does not support or endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or
06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for
calibration verification.
These same policies apply as they relate to the use of non-GM accessories. Damage or failure
from the use or installation of a non-GM accessory will not be covered under warranty. Failure
resulting from the alteration or modification of the vehicle, including the cutting, welding or
disconnecting of the vehicle's original equipment parts and components will void the warranty.
Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal
inquiry at either the local, state or federal level that
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results from the alteration or modification of a vehicle using non-GM approved parts or accessories.
Dealers should be especially cautious of accessory companies that claim the installation of their
product will not void the factory warranty. Many times these companies have even given direction
on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from
finding out that is has been installed.
Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada
by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair
is to be made on the vehicle, even with the installation of such non-GM approved components, the
customer is to be made aware of General Motors position on this issue and is to sign the
appropriate goodwill documentation required by General Motors.
It is imperative for dealers to understand that by installing such devices, they are jeopardizing not
only the warranty coverage, but also the performance and reliability of the customer's vehicle.
Disclaimer
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Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 278
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
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Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 279
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
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2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
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Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 282
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026B
Date: April 07, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2010 model year and information about
retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number
09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle)
to stresses that were not tested by General Motors. It is because of these unknown stresses, and
the potential to alter reliability, durability and emissions performance, that GM has adopted a policy
that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty
coverage, to the powertrain and driveline components whenever the presence of a non-GM
(aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 283
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
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3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the
complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 285
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table above.
Disclaimer
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness
Routing Views
Engine Control Module: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
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Routing Views > Page 288
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness
Routing Views > Page 289
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C
Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Routing Views > Page 290
Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
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17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Rear of the Engine Compartment Components - 1 of 2
1 - Engine Control Module (ECM) 2 - Front Plenum Panel
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Engine Control Module: Diagrams
Component Connector End Views
Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 293
Engine Control Module (ECM) X2
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 295
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 296
Engine Control Module (ECM) X3
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 298
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Engine Control Module: Description and Operation
Engine Control Module Description
The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent
driveability and fuel economy. The engine control module (ECM) is the control center of this
system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors
the information from various sensors and other inputs, and controls the systems that affect vehicle
performance and emissions. The ECM also performs the diagnostic tests on various parts of the
system. The ECM can recognize operational problems and alert the driver via the malfunction
indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble
code (DTC). The problem area is identified by the particular DTC that is set. The control module
supplies a buffered voltage to various sensors and switches. Review the components and wiring
diagrams in order to determine which systems are controlled by the ECM.
Malfunction Indicator Lamp (MIL) Operation
The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display
as either SERVICE ENGINE SOON or one of the following symbols when commanded ON:
The MIL indicates that an emissions related fault has occurred and vehicle service is required.
The following is a list of the modes of operation for the MIL:
* The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to
ensure the MIL is able to illuminate.
* The MIL turns OFF after the engine is started if a diagnostic fault is not present.
* The MIL remains illuminated after the engine is started if the control module detects a fault. A
diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an
emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test
Passed has been reported for the diagnostic test that originally caused the MIL to illuminate.
* The MIL flashes if the control module detects a misfire condition which could damage the catalytic
converter.
* When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the
ignition is ON.
* When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition
is cycled OFF and then ON.
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Engine Control Module: Service and Repair
Engine Control Module Replacement
Service of the engine control module (ECM) should normally consist of either replacement of the
ECM or electrically erasable programmable read only memory (EEPROM) programming. If the
diagnostic procedures call for the ECM to be replaced, the ECM should be inspected first to see if
the correct part is being used. If the correct part is being used, remove the faulty ECM and install
the new service ECM.
Caution:
* Turn the ignition OFF when installing or removing the control module connectors and
disconnecting or reconnecting the power to the control module (battery cable, powertrain control
module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control
module fuse, jumper cables, etc.) in order to prevent internal control module damage.
* Control module damage may result when the metal case contacts battery voltage. DO NOT
contact the control module metal case with battery voltage when servicing a control module, using
battery booster cables, or when charging the vehicle battery.
* In order to prevent any possible electrostatic discharge damage to the control module, do no
touch the connector pins or the soldered components on the circuit board.
* Remove any debris from around the control module connector surfaces before servicing the
control module. Inspect the control module connector gaskets when diagnosing or replacing the
control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant
intrusion into the control module.
* The replacement control module must be programmed.
Note: It is necessary to record the remaining engine oil life. If the replacement module is not
programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the
replacement module is not programmed with the remaining engine oil life, the engine oil will need
to be changed at 5 000 km (3,000 mi) from the last engine oil change.
Removal Procedure
1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine
oil life. 2. Remove the windshield washer solvent container. Refer to Windshield Washer Solvent
Container Replacement (See: Wiper and Washer
Systems/Windshield Washer Reservoir/Service and Repair).
3. Disengage the integral connector position assurance (CPA) retainer (1) on the body wiring
harness electrical connector. 4. Disconnect the body wiring harness electrical connector (2) from
the ECM.
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5. Disengage the integral CPA retainers on the engine wiring harness electrical connectors. 6.
Disconnect the engine wiring harness electrical connectors (2) from the ECM.
7. Lift up the ECM bracket tabs (2) and tilt the ECM (1) towards the front of the vehicle, removing
the ECM (1).
Installation Procedure
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1. Set the bottom of the ECM (1) into the bracket, and push the top of the ECM against the bracket.
Ensure that the tabs (2) secure the ECM (1).
2. Connect the engine wiring harness electrical connectors (2) to the ECM. 3. Engage the integral
CPA retainers on the engine wiring harness electrical connectors.
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4. Connect the body wiring harness electrical connector (2) to the ECM. 5. Engage the integral
CPA retainer (1) on the body wiring harness electrical connector. 6. If a NEW ECM was installed,
the ECM must be programmed. Refer to Control Module References (See: Testing and
Inspection/Programming
and Relearning).
7. Install the windshield washer solvent container. Refer to Windshield Washer Solvent Container
Replacement (See: Wiper and Washer
Systems/Windshield Washer Reservoir/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test).
Reference Information Schematic Reference
Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams)
Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning) for scan
tool information Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
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Page 308
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or
replace the battery positive cable to the underhood fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
‹› If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
‹› If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal,
and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM
for a short to ground. If the circuit tests normal, replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming
and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and
Inspection/Programming and Relearning)
* Engine Control Module Replacement (See: Engine Control Module/Service and Repair)
* Relay Replacement (Attached to Wire Harness) (See: Relays and Modules - Power and Ground
Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire
Harness))Relay Replacement (Within an Electrical Center) (See: Relays and Modules - Power and
Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an
Electrical Center))
Repair Verification
1. Install any components that have been removed or replaced during diagnosis.
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2. Perform any adjustment, programming, or setup procedures that are required when a
component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60
seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while
observing the powertrain relay circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain
Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the
appropriate diagnostic procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Diagrams
Air Injection Pump Relay: Diagrams
Component Connector End Views
Secondary Air Injection (AIR) Pump Relay (K18)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams
Fuel Pressure Control Module: Diagrams
Component Connector End Views
Fuel Pump Flow Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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318
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 325
Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test).
Reference Information Schematic Reference
Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams)
Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning) for scan
tool information Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
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Page 326
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or
replace the battery positive cable to the underhood fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
‹› If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
‹› If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal,
and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM
for a short to ground. If the circuit tests normal, replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming
and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and
Inspection/Programming and Relearning)
* Engine Control Module Replacement (See: Relays and Modules - Computers and Control
Systems/Engine Control Module/Service and Repair)
* Relay Replacement (Attached to Wire Harness) (See: Relays and Modules - Power and Ground
Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire
Harness))Relay Replacement (Within an Electrical Center) (See: Relays and Modules - Power and
Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an
Electrical Center))
Repair Verification
1. Install any components that have been removed or replaced during diagnosis.
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Page 327
2. Perform any adjustment, programming, or setup procedures that are required when a
component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60
seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while
observing the powertrain relay circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain
Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the
appropriate diagnostic procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
Air Bag Control Module: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 332
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 333
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 334
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 335
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 336
Air Bag Control Module: Diagrams
Component Connector End Views
Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 337
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 338
Air Bag Control Module: Service and Repair
Inflatable Restraint Sensing and Diagnostic Module Replacement
Removal Procedure
Warning
Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying
power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of
the vehicle. Failure to observe the correct installation procedure could cause SIR deployment,
personal injury, or unnecessary SIR system repairs.
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
2. Remove the floor console. Refer to Console Replacement (Large w/Manual or Auto
Transmission) (See: Body and Frame/Interior Moulding /
Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See:
Body and Frame/Interior Moulding / Trim/Console/Service and Repair).
3. Cut the carpet along the "I" cut pattern over the inflatable restraint sensing and diagnostic
module (SDM). 4. Fold the carpet back to expose the SDM.
5. Disconnect the electrical connector (2) from the SDM (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 339
6. Remove the nuts (2) retaining the SDM (1) to the floor studs (3). 7. Remove the SDM from the
vehicle.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the SDM (1) to the floor studs (3) with 3 nuts (2).
Tighten the SDM nuts to 9 Nm (79 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 340
2. Connect the electrical connector (2) to the SDM (1). 3. Fold the carpet back down over the SDM.
4. Install the floor console. Refer to Console Replacement (Large w/Manual or Auto Transmission)
(See: Body and Frame/Interior Moulding /
Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See:
Body and Frame/Interior Moulding / Trim/Console/Service and Repair).
Note: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may
set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after
enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to
ensure that the SDM is set properly.
5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
6. Program the SDM. Refer to Control Module References (See: Testing and
Inspection/Programming and Relearning).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Relay >
Component Information > Locations
Air Bag Relay: Locations
Component Connector End Views
Relay Inflatable Restraint
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Battery Control
Module > Component Information > Diagrams
Battery Control Module: Diagrams
Component Connector End Views
Generator Battery Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Charging System
Control Module > Component Information > Service and Repair > Generator Battery Control Module Replacement
Charging System Control Module: Service and Repair Generator Battery Control Module
Replacement
Generator Battery Control Module Replacement (V8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Charging System
Control Module > Component Information > Service and Repair > Generator Battery Control Module Replacement > Page
352
Charging System Control Module: Service and Repair Generator Battery Control Module
Replacement (4 and 5 Cylinder)
Generator Battery Control Module Replacement (4 and 5 Cylinder)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service
Bulletins > Tire Monitor System - TPM Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams
Control Module: Diagrams
Component Connector End Views
Transmission Control Module (TCM) (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 371
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 372
Control Module: Service and Repair
Transmission Control Module Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations
Wiper Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering
Wheel Button Activation
Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation
INFORMATION
Bulletin No.: 08-08-44-028
Date: August 28, 2008
Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio
Anomalies
Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior
HUMMER H2, H3 Models 2009 and Prior Saab 9-7X
All Vehicles with Steering Wheel Controls
This bulletin is being issued to provide a recommendation for vehicles with a customer concern of
the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or
radio muting or going silent when driving and turning the steering wheel.
The switches on the right hand side of the steering wheel are easily pressed and may inadvertently
be pressed when turning the steering wheel.
These concerns may be affected by the location of the steering wheel controls.
Recommendation
Do Not Replace The Radio
1. Please determine that the switch controls on the steering wheel are functioning correctly.
2. Ask the customer if their hand was in close proximity to the steering wheel controls when the
condition happened. Explain to the customer that bumping the controls would have caused this
undesired action. Explain to the customer the proper use and function of the steering wheel
controls.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Door Component Views
Power Door Lock Switch: Locations Door Component Views
Door Component Views
Driver Door Components
1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker
- Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch
(DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF)
Front Passenger Door Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Door Component Views > Page 388
1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door
Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Door Component Views > Page 389
Power Door Lock Switch: Locations Harness Routing Views
Harness Routing Views
Driver Door Harness Routing
1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside
Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body
Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver
Front Passenger Door Harness Routing
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Door Component Views > Page 390
1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front
Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body
Harness) 9 - X210 (Body Harness to Front Passenger Door Harness)
Right Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Door Component Views > Page 391
1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock
Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door
Harness)
Left Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Door Component Views > Page 392
1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness
to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Page 393
Power Door Lock Switch: Diagrams
Component Connector End Views
Door Lock/Window Switch - Driver X1 (A31/AU3)
Door Lock/Window Switch - Driver X2 (A31/AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Page 394
Door Lock/Window Switch - Passenger (A31/AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Page 395
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door
Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Driver Door
Door Lock Switch Replacement - Driver Door
Removal Procedure
1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the front
of the switch plate up to disengage clip. 3. Remove the switch plate out of the door trim panel
opening.
4. Disconnect the electrical connectors (3, 4) from the switches (2, 5). 5. Remove the switch plate
assembly (1) from the vehicle. 6. If replacing only the switches, remove the switches from the plate.
7. If replacing only the switch plate, retain the switches for transfer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door > Page 398
Installation Procedure
1. Install the switches (2, 5) to the switch plate (1). 2. Connect the electrical connectors (3, 4) to the
switches (2, 5).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the switch plate assembly to the door trim panel with the 2 screws.
Tighten the front door switch plate screws to 2 Nm (18 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door > Page 399
Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Passenger Front
Door Lock Switch Replacement - Passenger Front
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Door Component Views
Power Mirror Switch: Locations Door Component Views
Door Component Views
Driver Door Components
1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker
- Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch
(DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Door Component Views > Page 404
Power Mirror Switch: Locations Harness Routing Views
Harness Routing Views
Driver Door Harness Routing
1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside
Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body
Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 405
Power Mirror Switch: Diagrams
Component Connector End Views
Outside Rearview Mirror Switch (DE6)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations
Power Seat Switch: Locations
Passenger Compartment/Roof Component Views
Under the Driver Seat Components
1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1)
5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver
Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver
Passenger Seat Components - 2 of 2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 409
1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence
System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 410
Power Seat Switch: Diagrams
Component Connector End Views
Seat Adjuster Switch - Driver X1 (AG1)
Seat Adjuster Switch - Driver X2 (AG1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 411
Seat Adjuster Switch - Passenger (AG2)
Seat Lumbar Adjuster Switch - Driver (AG1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 412
Seat Lumbar Adjuster Switch - Passenger (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Power Seat Switch Replacement
Power Seat Switch: Service and Repair Power Seat Switch Replacement
Power Seat Switch Replacement
Removal Procedure
1. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel
Replacement (See: Body and Frame/Seats/Seat
Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement).
2. Remove the switch bezel from the seat assembly. Refer to Driver or Passenger Seat Adjuster
Switch Bezel Replacement (See: Body and
Frame/Seats/Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
3. Remove the buttons from the switch (2).
4. Release the tabs (1) that retain the seat switch (2) to the seat bezel.
5. Disconnect the power seat switch harness (1) from the seat harness.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Power Seat Switch Replacement > Page 415
6. Remove the power seat switch from the seat bezel.
Installation Procedure
1. Connect the power seat switch harness (1) to the seat harness.
2. Install the power seat switch (2) to the seat bezel. Verify that the retaining tabs (1) are fully
seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat
assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Body and
Frame/Seats/Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
5. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement
(See: Body and Frame/Seats/Seat Cushion/Service
and Repair/Seat Cushion Outer Trim Panel Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Power Seat Switch Replacement > Page 416
Power Seat Switch: Service and Repair Lumbar Switch Replacement
Lumbar Switch Replacement
Removal Procedure
1. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel
Replacement (See: Body and Frame/Seats/Seat
Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement).
2. Remove the switch bezel from the seat assembly. Refer to Driver or Passenger Seat Adjuster
Switch Bezel Replacement (See: Body and
Frame/Seats/Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
3. Remove the buttons from the switch (3).
4. Release the tabs (4) that retain the seat switch (3) to the seat bezel.
5. Disconnect the lumbar switch harness (1) from the seat harness.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Power Seat Switch Replacement > Page 417
6. Remove the lumbar switch from the seat bezel.
Installation Procedure
1. Connect the lumbar switch harness (1) to the seat harness.
2. Install the lumbar switch (3) to the seat bezel. Verify that the retaining tabs (4) are fully seated. 3.
Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Refer to
Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Body and
Frame/Seats/Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
5. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement
(See: Body and Frame/Seats/Seat Cushion/Service
and Repair/Seat Cushion Outer Trim Panel Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations
Sunroof / Moonroof Switch: Locations
Passenger Compartment/Roof Component Views
Front of the Headliner Components (CF5)
1 - Sunroof Switch X2 2 - Sunroof Opening 3 - G300 4 - Sunroof Motor 5 - Sunroof Switch 6 Sunroof Switch X1 7 - Sunroof Ground Lead
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations > Page 421
Sunroof / Moonroof Switch: Diagrams
Component Connector End Views
Sunroof Switch (CF5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations > Page 422
Sunroof / Moonroof Switch: Service and Repair
Sunroof Switch Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair
Acceleration/Deceleration Sensor: Service and Repair
Longitudinal Accelerometer Replacement
Removal Procedure
1. Remove the left front seat. Refer to Front Seat Replacement - Bucket (See: Body and
Frame/Seats/Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split
Bench Seat Replacement).
2. Access the sensor through service slit provided in the carpet. 3. Disconnect the longitudinal
accelerometer electrical connector.
4. Remove the nuts (1) from the longitudinal accelerometer. 5. Remove the longitudinal
accelerometer.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 427
1. Install the longitudinal accelerometer.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the longitudinal accelerometer nuts (1) and tighten to 9 Nm (80 lb in). 3. Connect the
longitudinal accelerometer electrical connector. 4. Install the left front seat. Refer to Front Seat
Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split
Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 432
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 433
Brake Fluid Level Sensor/Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 434
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 435
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 436
Brake Fluid Level Sensor/Switch: Diagrams
Component Connector End Views
Brake Fluid Level Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 437
Brake Fluid Level Sensor/Switch: Service and Repair
Brake Fluid Level Indicator Switch Replacement
Removal Procedure
1. Remove the electrical connector from the sensor. 2. Using a pair of needle nose pliers bend on a
90 degree angle, release the retaining clip. 3. Remove the sensor from the master cylinder.
Installation Procedure
1. Install the fluid sensor in the master cylinder. Make sure that the sensor is fully seated. 2. Install
the electrical connector
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Locations
Lateral Accelerometer: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Locations > Page 441
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Locations > Page 442
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Locations > Page 443
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Locations > Page 444
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Locations > Page 445
Lateral Accelerometer: Diagrams
Component Connector End Views
Yaw and Lateral Accelerometer Sensor (2WD) (JL4)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Locations > Harness Routing Views
Parking Brake Release Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 450
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 451
6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger
Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center
High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat
Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2
15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch
Switch 24 - Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to
Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200
(I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch
Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door
Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 452
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 453
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 454
Parking Brake Release Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Below the I/P Components - 2 of 2
1 - Park Brake Switch Connector 2 - Body Harness 3 - Park Brake Switch 4 - Park Brake Lever 5 Cowl Side Inner Panel
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Locations > Page 455
Parking Brake Release Switch: Diagrams
Component Connector End Views
Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Remove the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair).
2. Remove the electrical connector.
3. Remove the park brake warning lamp switch mounting bolt.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Service and Repair > Page 459
4. Remove the park brake warning lamp switch from the vehicle.
Installation Procedure
1. Install the park brake warning lamp switch.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the park brake warning lamp switch mounting bolt and tighten to 4 Nm (35 lb in).
3. Install the electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Service and Repair > Page 460
4. Install the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams
Traction Control Switch: Diagrams
Component Connector End Views
Traction Control Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Page 464
Traction Control Switch: Service and Repair
Electronic Traction Control Switch Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
Wheel Speed Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page
469
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page
470
Wheel Speed Sensor: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page
471
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page
472
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page
473
Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views
Wheels/Vehicle Underbody Component Views
Front Wheel Knuckle Components
1 - Wheel Speed Sensor (WSS) - Right Front 2 - Wheel Speed Sensor (WSS) - Left Front
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Page 474
Wheel Speed Sensor: Diagrams
Component Connector End Views
Wheel Speed Sensor (WSS) - Left Front
Wheel Speed Sensor (WSS) - Right Front
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Page 475
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement
Front Wheel Speed Sensor Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction
Control/Service Precautions/Technician Safety Information/Brake Dust Warning ).
1. Within the engine compartment, disconnect the wheel speed sensor electrical connector (1). 2.
Release the wheel speed sensor harness connector from the wheelhouse. 3. Raise and support
the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and
Repair). 4. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation
(See: Maintenance/Wheels and Tires/Service and Repair
).
5. Release the wheel speed sensor harness clips (1) from the suspension upper control arm.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 478
6. Release the wheel speed sensor harness grommet (1) from the mounting bracket.
7. Remove the wheel speed sensor harness bracket bolt (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 479
8. Thoroughly clean the wheel speed sensor mounting area of the steering knuckle of any dirt and
debris. 9. Remove the wheel speed sensor bolt (1).
Note: Do not pry or lever against the wheel speed sensor to remove.
10. Carefully remove the wheel speed sensor from the suspension knuckle by pulling straight
upward.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 480
1. Install the wheel speed sensor to the suspension knuckle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the wheel speed sensor bolt (1) and tighten to 8 Nm (71 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 481
3. Install the wheel speed sensor harness bracket bolt (1) and tighten to 9 Nm (80 lb in).
4. Install the wheel speed sensor harness grommet (1) to the mounting bracket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 482
5. Install the wheel speed sensor harness clips (1) to the suspension upper control arm.
6. Install the wheel speed sensor harness connector to the wheelhouse. 7. Connect the wheel
speed sensor electrical connector (1). 8. Install the tire and wheel assembly. Refer to Tire and
Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9.
Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnostic System
Check - Vehicle).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 483
Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement
Rear Wheel Speed Sensor Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction
Control/Service Precautions/Technician Safety Information/Brake Dust Warning ).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the wheel speed sensor bolts (1).
3. Remove the wheel speed sensor (1) from the drum brake backing plate by carefully pulling
straight outward.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 484
4. Release the wheel speed sensor harness retainers (1) on the rear park brake cable.
Release the harness from the retainers.
5. Disconnect the wheel speed sensor electrical connector (1). 6. Release the electrical connector
and harness retainer (2) from the frame. 7. Remove the wheel speed sensor assembly.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 485
1. Position the wheel speed sensor assembly to the vehicle. 2. Connect the wheel speed sensor
electrical connector (1). 3. Install the electrical connector and harness retainer (2) to the frame.
4. Position the wheel speed sensor harness to the retainers (1) on the rear park brake cable. 5.
Fasten the wheel speed sensor harness retainers.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 486
6. Install the wheel speed sensor (1) to the drum brake backing plate.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. Install the wheel speed sensor bolts (1) and tighten to 17 Nm (13 lb ft). 8. Lower the vehicle. 9.
Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnostic System
Check - Vehicle).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations
Yaw Rate Sensor: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 490
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 491
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 492
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 493
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 494
Yaw Rate Sensor: Diagrams
Component Connector End Views
Yaw and Lateral Accelerometer Sensor (2WD) (JL4)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 495
Yaw Rate Sensor: Service and Repair
Vehicle Yaw Sensor Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 501
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 502
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining
and Filling (Static Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See:
Engine, Cooling and Exhaust/Cooling System/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant
temperature (ECT) sensor.
3. Remove the ECT sensor (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 503
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent. 2. Install the ECT sensor (1).
Tighten the sensor to 20 Nm (15 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the
cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 504
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise
Control) > Component Information > Locations
Brake Switch (Cruise Control): Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise
Control) > Component Information > Locations > Page 509
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise
Control) > Component Information > Locations > Page 510
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise
Control) > Component Information > Locations > Page 511
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise
Control) > Component Information > Locations > Page 512
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise
Control > Component Information > Adjustments
Clutch Switch: Adjustments
Clutch Pedal Cruise Control Release Switch Adjustment
1. Disconnect the clutch release switch electrical connector (2).
2. Rotate the clutch release switch (4) counterclockwise, allowing the retainer (5) to release. 3. Pull
the clutch pedal to full stop. 4. While holding the clutch pedal at full stop, push the switch (4) inward
fully until the switch body contacts the clutch pedal arm.
At this point the plunger in the switch (4) should be pushed in.
5. Rotate the switch (4) clockwise until a "click" is heard.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise
Control > Component Information > Adjustments > Page 516
6. Connect the clutch release switch electrical connector (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise
Control > Component Information > Adjustments > Page 517
Clutch Switch: Service and Repair
Clutch Pedal Cruise Control Release Switch Replacement
Removal Procedure
1. Disconnect the clutch release switch electrical connector (2).
2. Complete the following in order to remove the clutch release switch (4) from the clutch pedal
bracket (1):
1. Rotate the switch (4) counterclockwise. 2. Pull the switch (4) from the retainer (5). 3. Push the
locking tabs inward to release the retainer (5).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise
Control > Component Information > Adjustments > Page 518
1. Slide only the clutch release switch retainer (5) into the clutch pedal bracket (1), until the locking
tabs are fully engaged. 2. Adjust the clutch release switch. Refer to Clutch Pedal Cruise Control
Release Switch Adjustment (See: Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams
Cruise Control Switch: Diagrams
Component Connector End Views
Cruise Control Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Page 522
Cruise Control Switch: Adjustments
Cruise Release Switch Adjustment
1. Disconnect the cruise control release switch electrical connector (1).
2. Rotate the cruise release switch counterclockwise, allowing the retainer to release. 3. Pull the
brake pedal rearward to full stop. 4. While holding the brake pedal in position rearward, push the
switch inward fully until the switch body contacts the brake pedal arm.
At this point the plunger in the switch should be pushed in.
5. Rotate the switch clockwise until a "click" is heard.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Page 523
6. Connect the cruise control release switch electrical connector (1). 7. The switch is properly
adjusted when there is 7 mm (0.28 in) clearance between the end of the barrel and the striker
plate.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Page 524
Cruise Control Switch: Service and Repair
Cruise Control Release Switch Replacement
Removal Procedure
1. Disconnect the electrical connector from the cruise release switch. 2. Complete the following in
order to remove the cruise release switch from the brake pedal bracket:
1. Rotate the switch counter clockwise. 2. Pull the switch from the retainer. 3. Push the locking tabs
inward to release the retainer.
Installation Procedure
1. Connect the electrical connector to the cruise release switch.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Page 525
2. Adjust the cruise release switch. Refer to Cruise Release Switch Adjustment (See: Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Locations
Oil Pressure Sender: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Locations > Page 530
Oil Pressure Sender: Diagrams
Component Connector End Views
Engine Oil Pressure (EOP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor >
Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Special Tools
J 41712 Oil Pressure Switch Socket
Removal Procedure
1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and
Repair).
2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor.
3. If not equipped with active fuel management perform the following step, using J 41712 or
equivalent, remove the oil pressure sensor (706) and
washer (707).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor >
Component Information > Service and Repair > Page 534
4. If equipped with active fuel management perform the following step, using J 41712 or equivalent,
remove the oil pressure sensor (706) and
washer (707).
Installation Procedure
1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids,
Lubricants, and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. If equipped with active fuel management perform the following step, using J 41712 or equivalent.
Install the oil pressure sensor (706) and washer
(707). Tighten the sensor to 35 Nm (26 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor >
Component Information > Service and Repair > Page 535
3. If not equipped with active fuel management, perform the following step, using J 41712 or
equivalent. Install the oil pressure sensor (706) and
washer (707).
4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the
sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement
(See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Locations > Harness Routing Views
Evaporator Temperature Sensor / Switch: Locations Harness Routing Views
Harness Routing Views
HVAC Harness Routing
1 - Evaporator Temperature Sensor (C60) 2 - X203 (I/P Harness to the HVAC Harness) 3 Recirculation Actuator (C60) 4 - Blower Motor 5 - J202 6 - Blower Motor Resistor Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Locations > Harness Routing Views > Page 541
Evaporator Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component
Views
Instrument Panel/Center Console Component Views
Behind the I/P Components
1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation
Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Locations > Page 542
Evaporator Temperature Sensor / Switch: Diagrams
Component Connector End Views
Evaporator Temperature Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Locations > Page 543
Evaporator Temperature Sensor / Switch: Service and Repair
Evaporator Temperature Sensor Replacement
Removal Procedure
1. Remove the radio. Refer to Radio Replacement (See: Accessories and Optional
Equipment/Radio, Stereo, and Compact
Disc/Radio/Stereo/Service and Repair/Radio Replacement).
2. Remove the mounting screw from the evaporator temperature control module. 3. Disconnect the
electrical connector from the control module. 4. Cut the evaporator temperature sensor wire near
the control module.
Note: *
Note the mounting position of the evaporative temperature sensor (a, b) and use these
measurements upon installation.
* If you are replacing only the control module, proceed to Step 4 of the Installation Procedure.
5. Remove the evaporator core. Refer to Air Conditioning Evaporator Core Replacement (See:
Heating and Air Conditioning/Evaporator
Core/Service and Repair).
6. Using needle nose pliers, carefully remove the evaporator temperature sensor from the
evaporator core.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Locations > Page 544
1. Install the evaporator temperature sensor to the evaporator core. Place the sensor
approximately 3.5 cm (1.4 in) from the side (a) and 5 cm (2 in)
from the bottom (b) corner of the evaporator core.
Note: Improper wire alignment will pinch and may cut the sensor wires.
2. Align the evaporator temperature sensor wires with the opening in the upper HVAC module
case. 3. Install the evaporator core. Refer to Air Conditioning Evaporator Core Replacement (See:
Heating and Air Conditioning/Evaporator
Core/Service and Repair).
4. Cut the evaporator temperature sensor from the replacement assembly. 5. Connect the original
sensor wire to the replacement assembly. Refer to Splicing Copper Wire Using Splice Sleeves
(See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Connect the electrical connector to the evaporator temperature control module.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. Install the mounting screw to the control module. Tighten the screw to 1.9 Nm (17 lb in). 8. Install
the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo,
and Compact Disc/Radio/Stereo/Service
and Repair/Radio Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
Refrigerant Pressure Sensor / Switch: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page
549
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page
550
Refrigerant Pressure Sensor / Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page
551
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page
552
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Page 553
Refrigerant Pressure Sensor / Switch: Diagrams
Component Connector End Views
A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Page 554
Refrigerant Pressure Sensor / Switch: Service and Repair
Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Locations > Harness Routing Views
Dimmer Switch: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Locations > Harness Routing Views > Page 560
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Locations > Harness Routing Views > Page 561
Dimmer Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Locations > Page 562
Dimmer Switch: Diagrams
Component Connector End Views
Headlamp and Panel Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Harness Routing Views
Door Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Harness Routing Views > Page 567
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Harness Routing Views > Page 568
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Left Rear Door Harness Routing (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Harness Routing Views > Page 569
1 - Speaker - Left Rear Door 2 - X312 (Body Harness to Left Rear Door Harness) 3 - X316 (Body
Harness to Left Rear Door Harness) 4 - Seat Belt Pretensioner - Left Front 5 - Door Jamb Switch Driver
Right Rear Door Harness Routing (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Harness Routing Views > Page 570
1 - Speaker - Right Rear Door 2 - Door Jamb Switch - Front Passenger 3 - Seat Belt Pretensioner Right Front 4 - X317 (Body Harness to Right Rear Door Harness) 5 - X311 (Body Harness to Right
Rear Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Harness Routing Views > Page 571
Door Switch: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Left B-Pillar Components (Regular Cab)
1 - Door Jamb Switch - Driver
Left B-Pillar and C-Pillar Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Harness Routing Views > Page 572
1 - Door Jamb Switch - Left Rear 2 - Door Jamb Switch - Driver
Right B-Pillar Components (Regular Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Harness Routing Views > Page 573
1 - Door Jamb Switch - Passenger
Right B-Pillar and C-Pillar Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Harness Routing Views > Page 574
1 - Door Jamb Switch - Right Rear 2 - Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Harness Routing Views > Page 575
Door Switch: Locations Door Component Views
Door Component Views
Left Rear Door Frame Components (Extended Cab)
1 - Door Jamb Switch - Driver
Right Rear Door Frame Components (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Harness Routing Views > Page 576
1 - Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Page 577
Door Switch: Diagrams
Component Connector End Views
Door Jamb Switch - Driver
Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Page 578
Door Jamb Switch - Left Rear (Crew Cab)
Door Jamb Switch - Right Rear (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Page 579
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Page 580
Door Switch: Service and Repair
Door Jamb Switch Replacement
Removal Procedure
1. Open the door. 2. Remove the screw retaining the door jamb switch (1) to the body. 3. Remove
the door jamb switch (1) from the body. 4. Disconnect the electrical connector from the switch.
Installation Procedure
1. Connect the electrical connector to the door jamb switch (1). 2. Install the door jamb switch (1) to
the body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Page 581
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the screw retaining the door jam switch to the body.
Tighten the door jamb switch screw to 1.5 Nm (13 lb in).
4. Close the door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams
Fuel Gauge Sender: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
Outside Temperature Display Sensor: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Front of the Engine Compartment Components
1 - Ambient Air Temperature (AAT) Sensor (DF8) 2 - Horn Assembly 3 - Inflatable Restraint Front
End Sensor - Left 4 - Inflatable Restraint Front End Sensor - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page
589
Outside Temperature Display Sensor: Locations Harness Routing Views
Harness Routing Views
Forward Lamp Harness Routing
1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn
Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right
11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low
Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body
Harness) 16 - X103 (Forward Lamp Harness to Body Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page
590
17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness
(TT5) 19 - Forward Lamp Harness (-TT5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Locations > Page 591
Outside Temperature Display Sensor: Service and Repair
Ambient Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air inlet grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and
Repair). 2. Disconnect the electrical connector to the ambient air temperature sensor.
3. Release the tabs (1) retaining the sensor to the radiator support bracket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Locations > Page 592
4. Remove the sensor (1) from the radiator support bracket.
Installation Procedure
1. Position the sensor (1) to the radiator support bracket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Locations > Page 593
2. Install the sensor ensuring the retaining tabs (1) are fully seated to the radiator support bracket.
3. Connect the electrical connector to the ambient air temperature sensor. 4. Install the air inlet
grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake
Warning Switch > Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Remove the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair).
2. Remove the electrical connector.
3. Remove the park brake warning lamp switch mounting bolt.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake
Warning Switch > Component Information > Service and Repair > Page 597
4. Remove the park brake warning lamp switch from the vehicle.
Installation Procedure
1. Install the park brake warning lamp switch.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the park brake warning lamp switch mounting bolt and tighten to 4 Nm (35 lb in).
3. Install the electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake
Warning Switch > Component Information > Service and Repair > Page 598
4. Install the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views
Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 604
Ambient Light Sensor: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 605
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light
Sensor > Component Information > Locations > Page 606
Ambient Light Sensor: Diagrams
Component Connector End Views
Ambient Light Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light
Sensor > Component Information > Locations > Page 607
Ambient Light Sensor: Service and Repair
Ambient Light Sensor Replacement
Removal Procedure
1. Carefully use a flat-bladed tool, and remove the sensor from the upper portion of the instrument
panel (I/P).
2. Disconnect the electrical connector (2) from the sensor ensuring the connector does NOT fall
through the hole in the I/P. 3. Remove the sensor from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light
Sensor > Component Information > Locations > Page 608
1. Connect the electrical connector (2) to the sensor.
2. Align the sensor to the I/P for installation. 3. Apply downward pressure to the sensor head in
order to seat the sensor to the I/P.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp
Switch > Component Information > Locations
Backup Lamp Switch: Locations
Powertrain Component Views
Right Side of the Transmission Components (MA5)
1 - Backup Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp
Switch > Component Information > Locations > Page 612
Backup Lamp Switch: Diagrams
Component Connector End Views
Backup Lamp Switch (MA5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp
Switch > Component Information > Locations > Page 613
Backup Lamp Switch: Service and Repair
Backup Lamp Switch Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the backup lamp switch electrical connector (1) at the pigtail. 3. Open the tie strap
securing the pigtail to the transmission.
4. Remove the backup lamp switch with the aluminum washer.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp
Switch > Component Information > Locations > Page 614
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
1. Install the backup lamp switch with a NEW aluminum washer into the transmission case.
Tighten the backup lamp switch to 44 Nm (32 lb ft).
2. Secure the pigtail to the transmission with the tie strap. 3. Connect the backup lamp switch
electrical connector (1) at the pigtail. 4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON
Technical Service Bulletin # 09049A Date: 110314
Recall - Brake Lamps Inoperative/Continuously ON
SAFETY
Bulletin No.: 09049A
Date: March 14, 2011
Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination
Models:
2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida,
Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas,
U.S. Virgin Islands, Utah
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s). Please discard all copies of bulletin 09049, issued July 2010.
Condition
General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch. Performance of the brakes is not
affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could
become inoperative.
Correction
Dealers are to install a new brake lamp switch assembly.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles
registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New
Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these
VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate
Vehicle History link. Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report
available if they have no involved vehicles currently assigned.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 623
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
Parts required to complete this recall are to be obtained from General Motors Customer Care and
Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal
orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts
should be ordered on a CSO = Customer Special Order.
Service Procedure
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Customer Reimbursement - For GM US
All customer requests for reimbursement of previously paid repairs for the recall condition will be
handled by the Customer Assistance Center, not by dealers.
Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section
6.1.12, for specific procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs for the recall condition are to be
submitted to the dealer by August 31, 2011.
All reasonable customer paid receipts should be considered for reimbursement. The amount to be
reimbursed will be limited to the amount the repair would have cost if completed by an authorized
General Motors dealer.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a
description of the repair, and the person or entity performing the repair.
Claims for customer reimbursement on previously paid repairs are to be submitted as required by
WINS.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement verification.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 624
* The amount identified in the "Net Item" column should represent the dollar amount reimbursed to
the customer.
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
included with this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the attached sample letter.
Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions)
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a
recall of this type must be adequately repaired within a reasonable time after the customer has
tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not adequately repaired
within a reasonable time, the customer may be entitled to an identical or reasonably equivalent
vehicle at no charge or to a refund of the purchase price less a reasonable allowance for
depreciation. To avoid having to provide these burdensome remedies, every effort must be made
to promptly schedule an appointment with each customer and to repair their vehicle as soon as
possible. In the recall notification letters, customers are told how to contact the US National
Highway Traffic Safety Administration if the recall is not completed within a reasonable time.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers' possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
Disclaimer
Owner Letter
Owner Letter
(Letter sent to customers in Phase 1 Notification)
Dear General Motors Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 625
continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as
designed due to contamination in the switch. Performance of the brakes is not affected. However,
this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps
to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions
and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative.
What will we do? When parts are available after August 2, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment on or
after August 2, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the Owner Center at www.gmownercenter.com.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049
Division Owner Letter
Division Owner Letter
(Letter sent to customer in Phase 2 notification)
Dear General Motors Customer:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 626
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
- Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work
as designed due to contamination in the switch. Performance of the brakes is not affected.
However, this condition could cause the simultaneous loss of all brake lamps or cause all of the
brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could
become inoperative.
What will we do? When parts are available after August 26, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment onor
after August 26, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
GM dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049-2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On
Technical Service Bulletin # 09186B Date: 110314
Campaign - Brake Lamps Inoperative Or Continuously On
SPECIAL COVERAGE
Bulletin No.: 09186B
Date: March 14, 2011
Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR
CONTINUOUS ILLUMINATION
Models:
2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030.
If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010.
Condition
Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may
comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be
caused by contamination in the brake lamp switch. The performance of the brakes is not affected.
Also, if equipped, they may comment about the loss of cruise control.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 7 years or 100,000
miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership.
Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to
the customer.
For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after
September 28, 2010, are covered by this special coverage and must be submitted using the labor
operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010,
must be submitted to the Service Contract provider.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built
within the following VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable
Warranties section in the Global Warranty Management system.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On > Page 631
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of
these switches on their shelves. Please verify your dealer inventory before ordering additional
quantities.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter shown in this bulletin - actual divisional letter may vary slightly).
Service Procedure
Note
Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the
vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Warranty Transaction Information
Submit a claim using the table below.
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must
have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000
km, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On > Page 632
the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Disclaimer
Owner Letter
Owner Letter
Dear GM Customer:
As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your
satisfaction with our product is very important to us.
This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado
and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch
could cause the loss of brake lamps or continuous illumination of the brake lamps. The
performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it
may become inoperative.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the brake
lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon
vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles
(160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis
or repair for conditions other than the condition described above is not covered under this special
coverage program.
What You Should Do: Repairs and adjustments qualifying under this special coverage must be
performed by a General Motors dealer. If you believe your vehicle has the condition described
above, you may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by December 31, 2011. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
General Motors Corporation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On > Page 633
Enclosure
09186
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > NHTSA09V310000 > Jul > 09 >
Recall 09V310000: Brake Lamp Switch Defect
Brake Light Switch: Recalls Recall 09V310000: Brake Lamp Switch Defect
VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2009 GMC/Canyon
2004-2009 Isuzu/I-280 2006 Isuzu/I-290 2007-2008 Isuzu/I-350 2006 Isuzu/I-370 2007-2008
MANUFACTURER: General Motors Corp.
MFR'S REPORT DATE: July 28, 2009
NHTSA CAMPAIGN ID NUMBER: 09V310000
NHTSA ACTION NUMBER: RQ09001 COMPONENT: Exterior Lighting: Brake Lights: Switch
POTENTIAL NUMBER OF UNITS AFFECTED: 185903
SUMMARY: GM is recalling 185,903 model year 2004-2009 Chevrolet Colorado, Model year
2004-2009 GMC Canyon, model year 2006 Isuzu I-280, I-350, model year 2007-2008 Isuzu I-290,
and I-370, passenger vehicles originally sold in or currently registered in the states of Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch.
CONSEQUENCE: This condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash.
REMEDY: Dealers will inspect and replace the necessary components as specified in the recall
bulletin free of charge. GM anticipates that parts will be available by February 2010. A special
coverage for vehicles registered in all other states will be implemented in the same time frame. In
the interim, owners who experience the failure can obtain a free repair, however they will be
required to return when the new design part becomes available. Owners may contact Chevrolet at
1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or at
www.gmownercenter.com.
NOTES: GM recall No. 09049. Owners may also contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A >
Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON
Technical Service Bulletin # 09049A Date: 110314
Recall - Brake Lamps Inoperative/Continuously ON
SAFETY
Bulletin No.: 09049A
Date: March 14, 2011
Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination
Models:
2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida,
Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas,
U.S. Virgin Islands, Utah
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s). Please discard all copies of bulletin 09049, issued July 2010.
Condition
General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch. Performance of the brakes is not
affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could
become inoperative.
Correction
Dealers are to install a new brake lamp switch assembly.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles
registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New
Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these
VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate
Vehicle History link. Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report
available if they have no involved vehicles currently assigned.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A >
Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 643
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
Parts required to complete this recall are to be obtained from General Motors Customer Care and
Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal
orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts
should be ordered on a CSO = Customer Special Order.
Service Procedure
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Customer Reimbursement - For GM US
All customer requests for reimbursement of previously paid repairs for the recall condition will be
handled by the Customer Assistance Center, not by dealers.
Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section
6.1.12, for specific procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs for the recall condition are to be
submitted to the dealer by August 31, 2011.
All reasonable customer paid receipts should be considered for reimbursement. The amount to be
reimbursed will be limited to the amount the repair would have cost if completed by an authorized
General Motors dealer.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a
description of the repair, and the person or entity performing the repair.
Claims for customer reimbursement on previously paid repairs are to be submitted as required by
WINS.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement verification.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A >
Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 644
* The amount identified in the "Net Item" column should represent the dollar amount reimbursed to
the customer.
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
included with this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the attached sample letter.
Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions)
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a
recall of this type must be adequately repaired within a reasonable time after the customer has
tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not adequately repaired
within a reasonable time, the customer may be entitled to an identical or reasonably equivalent
vehicle at no charge or to a refund of the purchase price less a reasonable allowance for
depreciation. To avoid having to provide these burdensome remedies, every effort must be made
to promptly schedule an appointment with each customer and to repair their vehicle as soon as
possible. In the recall notification letters, customers are told how to contact the US National
Highway Traffic Safety Administration if the recall is not completed within a reasonable time.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers' possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
Disclaimer
Owner Letter
Owner Letter
(Letter sent to customers in Phase 1 Notification)
Dear General Motors Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A >
Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 645
continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as
designed due to contamination in the switch. Performance of the brakes is not affected. However,
this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps
to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions
and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative.
What will we do? When parts are available after August 2, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment on or
after August 2, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the Owner Center at www.gmownercenter.com.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049
Division Owner Letter
Division Owner Letter
(Letter sent to customer in Phase 2 notification)
Dear General Motors Customer:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A >
Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 646
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
- Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work
as designed due to contamination in the switch. Performance of the brakes is not affected.
However, this condition could cause the simultaneous loss of all brake lamps or cause all of the
brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could
become inoperative.
What will we do? When parts are available after August 26, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment onor
after August 26, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
GM dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049-2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B >
Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On
Technical Service Bulletin # 09186B Date: 110314
Campaign - Brake Lamps Inoperative Or Continuously On
SPECIAL COVERAGE
Bulletin No.: 09186B
Date: March 14, 2011
Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR
CONTINUOUS ILLUMINATION
Models:
2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030.
If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010.
Condition
Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may
comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be
caused by contamination in the brake lamp switch. The performance of the brakes is not affected.
Also, if equipped, they may comment about the loss of cruise control.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 7 years or 100,000
miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership.
Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to
the customer.
For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after
September 28, 2010, are covered by this special coverage and must be submitted using the labor
operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010,
must be submitted to the Service Contract provider.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built
within the following VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable
Warranties section in the Global Warranty Management system.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B >
Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 651
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of
these switches on their shelves. Please verify your dealer inventory before ordering additional
quantities.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter shown in this bulletin - actual divisional letter may vary slightly).
Service Procedure
Note
Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the
vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Warranty Transaction Information
Submit a claim using the table below.
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must
have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000
km, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B >
Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 652
the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Disclaimer
Owner Letter
Owner Letter
Dear GM Customer:
As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your
satisfaction with our product is very important to us.
This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado
and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch
could cause the loss of brake lamps or continuous illumination of the brake lamps. The
performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it
may become inoperative.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the brake
lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon
vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles
(160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis
or repair for conditions other than the condition described above is not covered under this special
coverage program.
What You Should Do: Repairs and adjustments qualifying under this special coverage must be
performed by a General Motors dealer. If you believe your vehicle has the condition described
above, you may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by December 31, 2011. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
General Motors Corporation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B >
Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 653
Enclosure
09186
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: >
NHTSA09V310000 > Jul > 09 > Recall 09V310000: Brake Lamp Switch Defect
Brake Light Switch: All Technical Service Bulletins Recall 09V310000: Brake Lamp Switch Defect
VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2009 GMC/Canyon
2004-2009 Isuzu/I-280 2006 Isuzu/I-290 2007-2008 Isuzu/I-350 2006 Isuzu/I-370 2007-2008
MANUFACTURER: General Motors Corp.
MFR'S REPORT DATE: July 28, 2009
NHTSA CAMPAIGN ID NUMBER: 09V310000
NHTSA ACTION NUMBER: RQ09001 COMPONENT: Exterior Lighting: Brake Lights: Switch
POTENTIAL NUMBER OF UNITS AFFECTED: 185903
SUMMARY: GM is recalling 185,903 model year 2004-2009 Chevrolet Colorado, Model year
2004-2009 GMC Canyon, model year 2006 Isuzu I-280, I-350, model year 2007-2008 Isuzu I-290,
and I-370, passenger vehicles originally sold in or currently registered in the states of Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch.
CONSEQUENCE: This condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash.
REMEDY: Dealers will inspect and replace the necessary components as specified in the recall
bulletin free of charge. GM anticipates that parts will be available by February 2010. A special
coverage for vehicles registered in all other states will be implemented in the same time frame. In
the interim, owners who experience the failure can obtain a free repair, however they will be
required to return when the new design part becomes available. Owners may contact Chevrolet at
1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or at
www.gmownercenter.com.
NOTES: GM recall No. 09049. Owners may also contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 658
Brake Light Switch: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 659
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 660
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 661
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 662
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 663
Brake Light Switch: Diagrams
Component Connector End Views
Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 664
Brake Light Switch: Adjustments
Stop Lamp Switch Adjustment
1. Rotate the switch counterclockwise, allowing the retainer to release. 2. Pull the brake pedal
rearward to full stop.
Important: Do not move the brake pedal during switch adjustment as this will cause an
over-adjusted switch which could cause brake drag.
3. While holding the brake pedal FIRMLY in position rearward, push the switch inward fully until the
switch body contacts the brake pedal arm
striker plate. At this point the plunger in the switch should be pushed in.
4. Rotate the switch clockwise until a "click" is heard. 5. The switch is properly adjusted when there
is 7 mm (0.028 in) clearance between the end of the switch barrel and the striker plate on the brake
pedal arm.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 665
Brake Light Switch: Service and Repair
Stop Lamp Switch Replacement
Removal Procedure
1. Disconnect the stop lamp switch electrical connectors (1).
2. Rotate the switch counterclockwise. 3. Remove the switch from the bracket. 4. Remove the
switch from the vehicle.
Installation Procedure
1. Position the switch near the bracket. 2. Ensure the switch key-way is properly indexed to the
plastic retainer. 3. Install and adjust the switch. Refer to Stop Lamp Switch Adjustment (See:
Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 666
4. Connect the stop lamp switch electrical connectors (1). 5. Check the switch for proper operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch
> Component Information > Locations
Combination Switch: Locations
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views
Door Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 674
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 675
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Left Rear Door Harness Routing (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 676
1 - Speaker - Left Rear Door 2 - X312 (Body Harness to Left Rear Door Harness) 3 - X316 (Body
Harness to Left Rear Door Harness) 4 - Seat Belt Pretensioner - Left Front 5 - Door Jamb Switch Driver
Right Rear Door Harness Routing (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 677
1 - Speaker - Right Rear Door 2 - Door Jamb Switch - Front Passenger 3 - Seat Belt Pretensioner Right Front 4 - X317 (Body Harness to Right Rear Door Harness) 5 - X311 (Body Harness to Right
Rear Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 678
Door Switch: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Left B-Pillar Components (Regular Cab)
1 - Door Jamb Switch - Driver
Left B-Pillar and C-Pillar Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 679
1 - Door Jamb Switch - Left Rear 2 - Door Jamb Switch - Driver
Right B-Pillar Components (Regular Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 680
1 - Door Jamb Switch - Passenger
Right B-Pillar and C-Pillar Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 681
1 - Door Jamb Switch - Right Rear 2 - Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 682
Door Switch: Locations Door Component Views
Door Component Views
Left Rear Door Frame Components (Extended Cab)
1 - Door Jamb Switch - Driver
Right Rear Door Frame Components (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 683
1 - Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Page 684
Door Switch: Diagrams
Component Connector End Views
Door Jamb Switch - Driver
Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Page 685
Door Jamb Switch - Left Rear (Crew Cab)
Door Jamb Switch - Right Rear (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Page 686
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Page 687
Door Switch: Service and Repair
Door Jamb Switch Replacement
Removal Procedure
1. Open the door. 2. Remove the screw retaining the door jamb switch (1) to the body. 3. Remove
the door jamb switch (1) from the body. 4. Disconnect the electrical connector from the switch.
Installation Procedure
1. Connect the electrical connector to the door jamb switch (1). 2. Install the door jamb switch (1) to
the body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Page 688
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the screw retaining the door jam switch to the body.
Tighten the door jamb switch screw to 1.5 Nm (13 lb in).
4. Close the door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning
Switch > Component Information > Locations > Harness Routing Views
Hazard Warning Switch: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning
Switch > Component Information > Locations > Harness Routing Views > Page 693
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning
Switch > Component Information > Locations > Harness Routing Views > Page 694
Hazard Warning Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning
Switch > Component Information > Locations > Page 695
Hazard Warning Switch: Diagrams
Component Connector End Views
Hazard Warning Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning
Switch > Component Information > Locations > Page 696
Hazard Warning Switch: Service and Repair
Hazard Warning Switch Replacement
Removal Procedure
1. Remove the instrument panel (I/P) accessory trim plate. Refer to Instrument Panel Accessory
Trim Plate Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair).
2. Disconnect the hazard switch electrical connector.
Important: Ensure the tabs retaining the switch to the trim plate are released from the back side of
the trim panel.
3. Release the tabs retaining the switch to the trim plate.
4. Remove the switch (1) from the trim plate.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning
Switch > Component Information > Locations > Page 697
Installation Procedure
1. Position the switch (1) to the trim plate. 2. Ensure the switch key-way is indexed to the trim plate.
3. Install the switch to the trim plate ensuring the tabs are fully seated.
4. Connect the hazard switch electrical connector. 5. Install the I/P accessory trim plate. Refer to
Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Instrument Panel/Center Console Component Views
Headlamp Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Instrument Panel/Center Console Component Views > Page 702
Headlamp Switch: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Instrument Panel/Center Console Component Views > Page 703
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 704
Headlamp Switch: Diagrams
Component Connector End Views
Headlamp and Panel Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 705
Headlamp Switch: Service and Repair
Headlamp Switch Replacement
Removal Procedure
1. Remove the knee bolster trim panel. Refer to Driver Knee Bolster Panel Replacement (See:
Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
2. Remove the screw retaining the switch to the instrument panel (I/P). 3. Partially remove the
switch from the I/P. 4. Disconnect the switch electrical connector. 5. Remove the switch from the
vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 706
1. Position the switch to the I/P. 2. Connect the electrical connector to the switch. 3. Install the
switch to the I/P.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the screw retaining the switch to the I/P.
Tighten the screw to 2.5 Nm (22 lb in).
5. Install the knee bolster trim panel. Refer to Driver Knee Bolster Panel Replacement (See: Body
and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Diagrams
Horn Switch: Diagrams
Component Connector End Views
Horn Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Diagrams > Page 710
Horn Switch: Service and Repair
Steering Wheel Horn Switch Replacement
Removal Procedure
Warning: Refer to Servicing the SIR System Warning (See: Restraint Systems/Service
Precautions/Servicing the SIR System Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
2. Remove the Inflatable Restraint Steering Wheel module. Refer to Steering Wheel Inflatable
Restraint Module Replacement (See: Restraint
Systems/Air Bag Systems/Air Bag/Service and Repair).
3. Remove the horn plunger from the steering column by pressing inward to the stop and by
rotating the plunger 90 degrees.
4. Disconnect the screws (1, 4) from the steering wheel (3). 5. Remove the horn switch (2) from the
steering wheel (3).
Installation Procedure
1. Install the horn switch (2) to the steering wheel (3).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Connect the screws (1, 4) that secure the contact plate to the steering wheel (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Diagrams > Page 711
Tighten the screws to 5.5 Nm (49 lb in).
3. Install the horn plunger to the steering column. 4. Install the inflator module. Refer to Steering
Wheel Inflatable Restraint Module Replacement (See: Restraint Systems/Air Bag Systems/Air
Bag/Service and Repair).
5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
Turn Signal Switch: Locations
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement
Turn Signal Switch: Service and Repair Multifunction Turn Signal Switch Housing Replacement
Multifunction Turn Signal Switch Housing Replacement
Removal Procedure
1. Remove the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch
Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch
Replacement).
2. Remove the multifunction turn signal switch housing bolts. 3. Remove the multifunction turn
signal switch housing.
Installation Procedure
1. Install the multifunction turn signal switch housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the multifunction turn signal switch housing bolts.
Tighten the bolts to 2.5 Nm (22 lb in).
3. Install the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch
Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 717
Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement
Turn Signal Multifunction Switch Replacement
Removal Procedure
Note: The turn signal multifunction switch and Inflatable restraint steering wheel module coil are
serviced as an assembly.
1. Remove the steering wheel. Refer to Steering Wheel Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and
Repair/Steering Wheel Replacement).
2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
3. Disconnect any electrical connectors and remove the wiring harness from any retainers as
needed.
4. Remove the turn signal multifunction switch bolts. 5. Slide the multifunction turn signal switch off
of the steering column.
Installation Procedure
Note: A new multifunction turn signal switch will come precentered with a centering tab attached.
Do NOT remove the centering tab until installation is complete. Failure to follow procedure will
cause a misalignment of the multifunction turn signal switch and centering will be required.
If reusing the existing multifunction turn signal switch, you must center it. Refer to Inflatable
Restraint Steering Wheel Module Coil Centering ( See: Restraint Systems/Air Bag
Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Procedures).
1. Slide the multifunction turn signal switch onto the steering column.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 718
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the multifunction turn signal switch bolts.
Tighten the bolts to 7 Nm (62 lb in).
3. Route the wire harness assembly down the steering column.
4. Connect any electrical connectors and install the wiring harness through any retainers as
needed. 5. Remove the centering tab from the multifunction turn signal switch. 6. Install the
steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering
and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
7. Install the steering wheel. Refer to Steering Wheel Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and
Repair/Steering Wheel Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views
Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Behind the Left Side of the I/P Components
1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal
Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition
Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 725
Accelerator Pedal Position Sensor: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 726
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 727
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner -
Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 728
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 729
25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to
Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to
Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33
- Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 730
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 731
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP
sensor nuts. 3. Remove the APP sensor from the vehicle.
Installation Procedure
1. Position the APP sensor over the studs.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Page 732
2. Install the APP sensor nuts.
Tighten the APP sensor mounting nuts to 9 Nm (80 lb in).
3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure
full range of motion.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams
Air Flow Meter/Sensor: Diagrams
Component Connector End Views
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 736
Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Removal Procedure
Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not
dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do
not touch the sensing elements or allow anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct
only, to aid in installation.
1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor.
2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner
upper housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 737
Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The
arrow must point toward the engine.
1. Install the MAF/IAT sensor (2) to the air cleaner upper housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the MAF/IAT sensor screws (1).
Tighten the screws to 1.5 Nm (13 lb in).
3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Engine - Front (LH8)
1 - Throttle Body 2 - Camshaft Position (CMP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 741
Camshaft Position Sensor: Diagrams
Component Connector End Views
Camshaft Position (CMP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 742
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 746
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 747
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining
and Filling (Static Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See:
Engine, Cooling and Exhaust/Cooling System/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant
temperature (ECT) sensor.
3. Remove the ECT sensor (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 748
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent. 2. Install the ECT sensor (1).
Tighten the sensor to 20 Nm (15 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the
cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 749
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Powertrain Component Views
Engine - Right Side (LH8) (5.3L)
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
753
Crankshaft Position Sensor: Diagrams
Component Connector End Views
Crankshaft Position (CKP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair >
Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and
Charging/Starting System/Starter Motor/Service and
Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP)
sensor.
3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the
engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair >
Crankshaft Position Sensor Replacement > Page 756
1. Install the CKP sensor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the CKP sensor bolt.
Tighten the bolt to 25 Nm (18 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the
starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting
System/Starter Motor/Service and Repair
)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position
System Variation Learn (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Crankshaft Position Sensor Replacement > Page 757
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set.
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315 (See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If
any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain
Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Descriptions) for the applicable DTC that set.
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams
Fuel Level Sensor: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 761
Fuel Level Sensor: Service and Repair
Fuel Level Sensor Replacement
Removal Procedure
1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Pump/Service and Repair).
2. Disconnect the fuel level sensor electrical connector (1) from the module cover.
3. Complete the following in order to remove the fuel level sensor (1) from the module bucket:
1. Disengage the locking tabs on the sensor. 2. Slide the sensor upward from the bucket.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 762
1. Complete the following in order to install the fuel level sensor to the module bucket.
1. Align the edges of the sensor with the slots in the module bucket. 2. Slide the sensor down into
position, ensure the locking tabs are fully engaged.
2. Connect the fuel level sensor electrical connector (1) to the module cover. 3. Install the fuel tank
module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel
Delivery and Air
Induction/Fuel Pump/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL
ON/DTC's P0451/P0454 Set
Fuel Tank Pressure Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0451/P0454 Set
TECHNICAL
Bulletin No.: 10-06-04-001C
Date: December 08, 2010
Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure
Sensor Cover)
Models:
2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to
November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to
November 4, 2009) 2009-2010 Pontiac G5
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System).
Condition
Some customers may comment on a check engine light. Upon further investigation, a technician
may find one of the above DTCs.
Cause
This condition may be caused by normal water accumulation or condensation blocking the air
reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If
the signal varies during an Engine Off Natural Vacuum test, a false DTC could set.
Correction
Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI
diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield,
P/N 20893611. Clear the DTCs.
Chevrolet Colorado, Silverado and GMC Canyon, Sierra
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable
adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank
straps. 5. Lower the fuel tank halfway.
6. Locate the fuel tank pressure sensor (1).
7. Install the fuel tank pressure sensor cover, GM P/N 20893611.
Chevrolet Cobalt and Pontiac G5
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL
ON/DTC's P0451/P0454 Set > Page 771
2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls MIL ON/DTC's P0451/P0454 Set
Fuel Tank Pressure Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's
P0451/P0454 Set
TECHNICAL
Bulletin No.: 10-06-04-001C
Date: December 08, 2010
Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure
Sensor Cover)
Models:
2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to
November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to
November 4, 2009) 2009-2010 Pontiac G5
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System).
Condition
Some customers may comment on a check engine light. Upon further investigation, a technician
may find one of the above DTCs.
Cause
This condition may be caused by normal water accumulation or condensation blocking the air
reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If
the signal varies during an Engine Off Natural Vacuum test, a false DTC could set.
Correction
Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI
diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield,
P/N 20893611. Clear the DTCs.
Chevrolet Colorado, Silverado and GMC Canyon, Sierra
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable
adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank
straps. 5. Lower the fuel tank halfway.
6. Locate the fuel tank pressure sensor (1).
7. Install the fuel tank pressure sensor cover, GM P/N 20893611.
Chevrolet Cobalt and Pontiac G5
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls MIL ON/DTC's P0451/P0454 Set > Page 777
2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness
Routing Views
Fuel Tank Pressure Sensor: Locations Harness Routing Views
Harness Routing Views
Chassis Harness Routing
1 - Chassis Frame 2 - Fuel Tank Pressure (FTP) Sensor 3 - Fuel Pump and Sender Assembly 4 Evaporative Emission (EVAP) Canister Vent Solenoid 5 - X402 (Chassis Harness to Right Rear
Lamp Assembly) 6 - J404 7 - X401 (Chassis Harness to Left Rear Lamp Assembly) 8 - X400
(Chassis Harness to License Lamp Harness) 9 - J403 10 - J402 11 - J400 12 - J401 13 - J310 14 X102 (Body Harness to Chassis Harness)
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Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness
Routing Views > Page 780
Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views
Wheels/Vehicle Underbody Component Views
Rear of the Frame Components
1 - Evaporative Emission (EVAP) Canister Vent Solenoid 2 - Fuel Tank Pressure (FTP) Sensor 3 Fuel Pump and Sender Assembly 4 - Fuel Pump
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
781
Fuel Tank Pressure Sensor: Diagrams
Component Connector End Views
Fuel Tank Pressure (FTP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
782
Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor Replacement
Removal Procedure
1. Raise and support the vehicle, high enough to access the top of the fuel tank through the
wheelhouse liner. Refer to Lifting and Jacking the Vehicle
(See: Maintenance/Vehicle Lifting/Service and Repair).
2. If the vehicle is crew cab, lower the fuel tank. Refer to Fuel Tank Replacement (See: Powertrain
Management/Fuel Delivery and Air
Induction/Fuel Tank/Service and Repair).
3. Remove the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner
Replacement (See: Body and Frame/Fender/Rear
Fender/Rear Fender Liner/Service and Repair).
4. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor
(1). 5. Pull upward in order to remove the sensor from the fuel tank module.
Installation Procedure
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Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
783
1. Lightly lubricate the sensor seal with clean engine oil. 2. Press the sensor fully into the fuel tank
module. 3. Connect the chassis wiring harness electrical connector to the pressure sensor (1). 4.
Install the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner
Replacement (See: Body and Frame/Fender/Rear
Fender/Rear Fender Liner/Service and Repair).
5. If the vehicle is a crew cab, install the fuel tank. Refer to Fuel Tank Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Tank/Service and Repair).
6. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams
Intake Air Temperature Sensor: Diagrams
Component Connector End Views
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page
787
Intake Air Temperature Sensor: Service and Repair
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Removal Procedure
Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not
dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do
not touch the sensing elements or allow anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct
only, to aid in installation.
1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor.
2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner
upper housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page
788
Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The
arrow must point toward the engine.
1. Install the MAF/IAT sensor (2) to the air cleaner upper housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the MAF/IAT sensor screws (1).
Tighten the screws to 1.5 Nm (13 lb in).
3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Engine - Right Side (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 792
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 793
Knock Sensor: Diagrams
Component Connector End Views
Knock Sensor (KS) 1 (LH8)
Knock Sensor (KS) 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 794
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock
Sensor 1 Replacement
Knock Sensor: Service and Repair Knock Sensor 1 Replacement
Knock Sensor 1 Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS
retaining bolt. 4. Remove the KS (2) from the engine block.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock
Sensor 1 Replacement > Page 797
1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals
down.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock
Sensor 1 Replacement > Page 798
Knock Sensor: Service and Repair Knock Sensor 2 Replacement
Knock Sensor 2 Replacement
Removal Procedure
1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS)
through the wheelhouse. Refer to Lifting and Jacking
the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair).
2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body
and Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS
retaining bolt. 5. Remove the KS (1) from the engine block.
Installation Procedure
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock
Sensor 1 Replacement > Page 799
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals
rearward.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left
wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and
Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Powertrain Component Views
Engine - Right Side (LH8)
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Page 803
Manifold Pressure/Vacuum Sensor: Diagrams
Component Connector End Views
Manifold Absolute Pressure (MAP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Page 804
Manifold Pressure/Vacuum Sensor: Service and Repair
Manifold Absolute Pressure Sensor Replacement
Removal Procedure
1. Remove the upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute
pressure (MAP) sensor.
3. Remove the MAP sensor retainer (1) from the intake manifold. 4. Remove the MAP sensor (2)
from the intake manifold.
Installation Procedure
Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Page 805
1. Install the MAP sensor (2) into the intake manifold. 2. Install the MAP sensor retainer (2) to the
intake manifold.
3. Connect the engine wiring harness electrical connector (3) to the MAP sensor. 4. Install the
upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Special Tools
J 41712 Oil Pressure Switch Socket
Removal Procedure
1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and
Repair).
2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor.
3. If not equipped with active fuel management perform the following step, using J 41712 or
equivalent, remove the oil pressure sensor (706) and
washer (707).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page
809
4. If equipped with active fuel management perform the following step, using J 41712 or equivalent,
remove the oil pressure sensor (706) and
washer (707).
Installation Procedure
1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids,
Lubricants, and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. If equipped with active fuel management perform the following step, using J 41712 or equivalent.
Install the oil pressure sensor (706) and washer
(707). Tighten the sensor to 35 Nm (26 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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810
3. If not equipped with active fuel management, perform the following step, using J 41712 or
equivalent. Install the oil pressure sensor (706) and
washer (707).
4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the
sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement
(See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations
Oxygen Sensor: Locations
Powertrain Component Views
Rear of the Transmission Components
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 814
Oxygen Sensor: Diagrams
Component Connector End Views
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 (LH8)
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 815
Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (LH8)
Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 816
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive
Force and Oxygen Sensor Caution
Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution
Excessive Force and Oxygen Sensor Caution
Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Force and Oxygen Sensor Caution > Page 819
Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution
Heated Oxygen and Oxygen Sensor Caution
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive
Force and Oxygen Sensor Caution > Page 820
Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution
Heated Oxygen Sensor Resistance Learn Reset Caution
Caution: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive
Force and Oxygen Sensor Caution > Page 821
Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution
Silicon Contamination of Heated Oxygen Sensors Caution
Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4)
from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the
rear HO2S electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 824
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
4. Remove the HO2S (1).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 825
2. Install the HO2S (1).
Tighten the sensor to 42 Nm (31 lb ft).
3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S
electrical connector (4) to the engine wiring harness electrical connector (1). 5. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 826
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2)
from the engine wiring harness electrical connector (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 827
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
3. Remove the HO2S (2).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 828
2. Install the HO2S (2).
Tighten the sensor to 42 Nm (31 lb ft).
3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the
HO2S electrical connector (2) to the engine wiring harness electrical connector (3). 5. Lower the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 829
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1
Heated Oxygen Sensor Replacement - Bank 2 Sensor 1
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2)
from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the
rear HO2S electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 830
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
4. Remove the HO2S (1).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 831
2. Install the HO2S (1).
Tighten the sensor to 42 Nm (31 lb ft).
3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S
electrical connector (2) to the engine wiring harness electrical connector (1). 5. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 832
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2
Heated Oxygen Sensor Replacement - Bank 2 Sensor 2
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4)
from the engine wiring harness electrical connector (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 833
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
3. Remove the HO2S (2).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 834
2. Install the HO2S (2).
Tighten the sensor to 42 Nm (31 lb ft).
3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the
HO2S electrical connector (4) to the engine wiring harness electrical connector (3). 5. Lower the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations
Transmission Position Switch/Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Left Side of the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 838
1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 839
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 840
Transmission Position Switch/Sensor: Diagrams
Component Connector End Views
Park/Neutral Position (PNP) Switch (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 841
Transmission Position Switch/Sensor: Service and Repair
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
2. Remove the following parts: (89), (92), (88), (85) and (84)
3. Remove the manual shaft seal (82) with a screwdriver.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 842
1. Inspect the following items:
* Manual shaft (84) for damage or burrs
* Parking lock actuator assembly (85) for damage
* Manual shift detent lever with shaft position switch assembly (88) for damage or cracks
* Manual valve link (89) for damage
* Manual shift detent lever pin (92) discard - Do NOT reuse.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the following items:
* Manual shift detent lever with shaft position switch assembly (88)
* Parking lock actuator assembly (85)
* Manual shaft (84) (model dependent)
* NEW manual shift detent lever pin (92)
* Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft).
3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Vehicle Speed Sensor: Locations
Powertrain Component Views
Left Side of the Transmission Components (MA5)
Description
1 - Vehicle Speed Sensor (VSS)
Inside the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 846
36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift
Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid
Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC)
Pulse Width Modulation (PWM) Solenoid Valve
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 847
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 848
Vehicle Speed Sensor: Diagrams
Component Connector End Views
Vehicle Speed Sensor (VSS)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair >
Aisin AR5 - Manual Transmission
Vehicle Speed Sensor: Service and Repair Aisin AR5 - Manual Transmission
Vehicle Speed Sensor Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the vehicle speed sensor (VSS) electrical connector (2).
3. Remove the VSS with O-ring seal.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair >
Aisin AR5 - Manual Transmission > Page 851
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
1. Install the VSS with O-ring seal.
Tighten the vehicle speed sensor (VSS) to 17 Nm (13 lb ft).
2. Connect the VSS electrical connector (2). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair >
Aisin AR5 - Manual Transmission > Page 852
Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission
Vehicle Speed Sensor Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the wiring harness electrical
connector from the vehicle speed sensor.
3. Remove the harness connector. 4. Remove the bolt (2). 5. Remove the vehicle speed sensor
(1). 6. Remove the O-ring seal (3).
Installation Procedure
1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin
film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the bolt (2) and tighten to 11 Nm (97 lb in). 5. Connect the wiring harness electrical
connector to the vehicle speed sensor. 6. Lower the vehicle. 7. Refill the fluid as required.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views
Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Behind the Left Side of the I/P Components
1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal
Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition
Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 858
Accelerator Pedal Position Sensor: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 859
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 860
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner -
Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 861
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 862
25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to
Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to
Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33
- Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 863
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 864
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP
sensor nuts. 3. Remove the APP sensor from the vehicle.
Installation Procedure
1. Position the APP sensor over the studs.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 865
2. Install the APP sensor nuts.
Tighten the APP sensor mounting nuts to 9 Nm (80 lb in).
3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure
full range of motion.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams
Air Flow Meter/Sensor: Diagrams
Component Connector End Views
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 869
Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Removal Procedure
Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not
dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do
not touch the sensing elements or allow anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct
only, to aid in installation.
1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor.
2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner
upper housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 870
Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The
arrow must point toward the engine.
1. Install the MAF/IAT sensor (2) to the air cleaner upper housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the MAF/IAT sensor screws (1).
Tighten the screws to 1.5 Nm (13 lb in).
3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Engine - Front (LH8)
1 - Throttle Body 2 - Camshaft Position (CMP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 875
Camshaft Position Sensor: Diagrams
Component Connector End Views
Camshaft Position (CMP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 876
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Powertrain Component Views
Engine - Right Side (LH8) (5.3L)
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 880
Crankshaft Position Sensor: Diagrams
Component Connector End Views
Crankshaft Position (CKP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft
Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and
Charging/Starting System/Starter Motor/Service and
Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP)
sensor.
3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the
engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft
Position Sensor Replacement > Page 883
1. Install the CKP sensor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the CKP sensor bolt.
Tighten the bolt to 25 Nm (18 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the
starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting
System/Starter Motor/Service and Repair
)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position
System Variation Learn (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft
Position Sensor Replacement > Page 884
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set.
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315 (See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If
any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain
Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Descriptions) for the applicable DTC that set.
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
This vehicle has two different types of ignition lock cylinders based on what type of steering column
the vehicle is equipped with. The electric power steering (EPS) option, usually found on 4 cylinder
models, and the non EPS, usually found on 6 cylinder models, use different ignition lock cylinder
designs.
Ignition Lock Cylinder
The ignition lock cylinder uses all 10 key cut positions, 1-10 when counting from the key head. The
tumbler orientations alternate in adjacent locations from side to side with 5 tumblers on each side.
Important: The ignition lock cylinder tumblers (1) are not self retaining and must be held in place if
the key is not fully inserted in the lock cylinder (2), or until the lock cylinder (2) is assembled into
the case assembly (5).
1. Hold the uncoded cylinder assembly (2) positioned so the side with the security plug (3) faces to
the left of the key head. 2. Insert one tumbler spring (7) into each of the 4 tumbler spring holes. 3.
The first tumbler (1) to be loaded will be key cut position 1, the first number in the key code. Install
this tumbler in the tumbler slot closest to the
head of the lock cylinder (2), the end where the key is inserted.
4. Advancing one tumbler slot at a time, install tumblers 3, 5, and 7 sequentially on the same side
as tumbler 1. 5. Turn the lock cylinder over and insert one tumbler spring (7) into each of the 4
tumbler spring holes on the opposite side of the lock cylinder. 6. Insert tumbler 2 into the tumbler
slot closest to the head of the lock cylinder (2), the end where the key is inserted. 7. Advancing one
tumbler slot at a time, install tumblers 4, 6, and 8 sequentially on the same side as tumbler 2. 8.
Check for correct tumbler loading by holding the tumblers (1) in position and inserting the correct
key into the lock cylinder. All tumblers (1)
should be flush with the housing of the lock cylinder.
9. Lightly lubricate the tumblers and small detent recessed areas the tumblers are in with GM
Super Lube GM P/N 12346241 or equivalent light
lithium grease.
10. Take the slide piece and insert into the rotor. Ensure "Front of Sliding Piece" is facing the front
face of the rotor. If the slide piece is installed
incorrectly, the key cannot insert into the rotor due to no access to the ramp.
11. Install the pivot pin into the actuator lever and install the actuator lever into the ignition lock
cylinder housing. Ensure that the actuator lever is
inside of the lock cylinder housing at the end close to key insertion opening. Actuator lever should
pivot on the pin against spring tension.
12. Insert the key into the coded lock cylinder (2) and hold the lock cylinder positioned so the side
with the security plug (3) faces to the left of the key
head.
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Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Procedures > Page 890
13. Hold the ignition lock housing positioned so the security plug actuator lever (3) also faces to the
right of the key head. 14. Push the exposed end of the security plug actuator lever (3) toward the
center of the lock cylinder housing (1) and hold it. Insert the coded lock
cylinder (2) with the key in it into the ignition lock cylinder housing (1) until the cap is flush with the
housing.
15. Rotate the keyed lock cylinder counterclockwise slightly until it stops and detents outward
slightly. The key should be able to be removed and the
lock cylinder should remain in the housing.
16. Install the retaining clip (1) onto the coded lock cylinder where it comes out of the back of the
lock cylinder housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Procedures > Page 891
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Removal Procedure
1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition
Lock Cylinder Replacement). 2. Remove the multifunction turn signal switch housing. Refer to
Multifunction Turn Signal Switch Housing Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch
Housing Replacement).
3. Remove the shear bolt from the ignition lock cylinder case using a hammer and chisel. 4.
Remove the ignition lock cylinder case.
Installation Procedure
1. Install the ignition lock cylinder case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the ignition lock cylinder case bolt and tighten it until the head shears off. 3. Install the
multifunction turn signal switch. Refer to Multifunction Turn Signal Switch Housing Replacement
(See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch
Housing Replacement).
4. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock
Cylinder Replacement). 5. The passlock sensor is part of the ignition switch. If replacing the ignition
switch, a passlock relearn will be needed. Refer to Control Module
References (See: Testing and Inspection/Programming and Relearning).
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Removal Procedure
1. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
2. Turn the ignition lock cylinder to the accessory position. 3. Insert the 90 degree tip of a pick type
tool into the ignition lock cylinder access hole. 4. Push and hold the ignition lock cylinder retaining
pin down.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Procedures > Page 892
5. Pull the ignition lock cylinder away from the steering column.
Installation Procedure
1. Install the ignition lock cylinder by performing the following procedure:
1. Turn the ignition lock cylinder to the accessory position. 2. Push the ignition lock cylinder in until
the retaining pin locks it in place.
2. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Engine - Right Side (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 896
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 897
Knock Sensor: Diagrams
Component Connector End Views
Knock Sensor (KS) 1 (LH8)
Knock Sensor (KS) 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 898
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement
Knock Sensor: Service and Repair Knock Sensor 1 Replacement
Knock Sensor 1 Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS
retaining bolt. 4. Remove the KS (2) from the engine block.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement
> Page 901
1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals
down.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement
> Page 902
Knock Sensor: Service and Repair Knock Sensor 2 Replacement
Knock Sensor 2 Replacement
Removal Procedure
1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS)
through the wheelhouse. Refer to Lifting and Jacking
the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair).
2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body
and Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS
retaining bolt. 5. Remove the KS (1) from the engine block.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement
> Page 903
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals
rearward.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left
wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and
Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Door Component Views
Impact Sensor: Locations Door Component Views
Door Component Views
Driver Door Components
1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker
- Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch
(DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF)
Front Passenger Door Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Door Component Views > Page 909
1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door
Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Door Component Views > Page 910
Impact Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Front of the Engine Compartment Components
1 - Ambient Air Temperature (AAT) Sensor (DF8) 2 - Horn Assembly 3 - Inflatable Restraint Front
End Sensor - Left 4 - Inflatable Restraint Front End Sensor - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Door Component Views > Page 911
Impact Sensor: Locations Harness Routing Views
Harness Routing Views
Forward Lamp Harness Routing
1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn
Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right
11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low
Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body
Harness) 16 - X103 (Forward Lamp Harness to Body Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Door Component Views > Page 912
17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness
(TT5) 19 - Forward Lamp Harness (-TT5)
Driver Door Harness Routing
1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside
Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body
Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver
Front Passenger Door Harness Routing
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Door Component Views > Page 913
1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front
Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body
Harness) 9 - X210 (Body Harness to Front Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 914
Impact Sensor: Diagrams
Component Connector End Views
Inflatable Restraint Front End Sensor - Left
Inflatable Restraint Front End Sensor - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 915
Inflatable Restraint Passenger Presence System (PPS) Sensor
Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 916
Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement
Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement
Inflatable Restraint Front End Sensor Replacement
Removal Procedure
Warning
Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end
sensor make sure that it is securely fastened. Failure to observe the correct installation procedure
could cause SIR deployment, personal injury, or unnecessary SIR system repairs.
Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
2. Remove the grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and
Repair).
3. Loosen the fasteners (1) retaining the front discriminating sensors to the radiator support.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 919
4. Remove the sensor assembly from the radiator support.
5. Position the sensor assembly, to gain access to the electrical connector. 6. Remove the
connector-position assurance (CPA) from the sensor electrical connector. 7. Disconnect the sensor
electrical connector. 8. Remove the sensor from the vehicle.
Installation Procedure
1. Remove any dirt, grease, or other impurities from the mounting surfaces.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 920
2. Position the sensor near the radiator support. 3. Connect the sensor electrical connector. 4.
Install the CPA to the sensor electrical connector.
5. Install the sensor assembly to the radiator support.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 921
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the 2 fasteners (1) retaining the discriminating sensor assembly to the radiator support.
Tighten the bolts to 9 Nm (80 lb in).
7. Install the grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair).
8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 922
Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement
Inflatable Restraint Vehicle Rollover Sensor Replacement
Removal Procedure
Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
2. Fold back the carpet in order to gain access to the sensor. Refer to Floor Panel Carpet
Replacement (See: Body and Frame/Interior Moulding /
Trim/Carpet/Service and Repair).
3. Disconnect the electrical connector. 4. Remove the nuts securing the rollover sensor to the floor
panel.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 923
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the nuts securing the rollover sensor to the floor panel.
Tighten the screws to 10 Nm (88 lb in).
2. Connect the electrical connectors. 3. Install the carpet. Refer to Floor Panel Carpet Replacement
(See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair). 4. Enable the SIR
system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 924
Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement
Inflatable Restraint Side Impact Sensor Replacement
Removal Procedure
Warning
Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the
SIS make sure that it is securely fastened. Failure to observe the correct installation procedures
could cause SIR deployment, personal injury, or unnecessary SIR system repairs.
Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
2. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair).
3. Peel the rear half of the water deflector away from the door in order to access the side impact
sensor. 4. Remove the screws that retain the side impact sensor to the door. 5. Disconnect the
impact sensor electrical connector from the side impact sensor. 6. Remove the side impact sensor
from the door.
Installation Procedure
1. Remove any dirt, grease, or other impurities from the mounting surface.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 925
2. Position the side impact sensor horizontally to the door. 3. Connect the electrical connector to
the side impact sensor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the screws which retain the side impact sensor to the door.
Tighten the screws to 9 Nm (79 lb in).
5. Fully seat the water deflector to the door. 6. Install the door trim panel. Refer to Front Side Door
Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Panel/Service and Repair).
7. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Tension
Sensor > Component Information > Locations
Seat Belt Tension Sensor: Locations
Passenger Compartment/Roof Component Views
Passenger Seat Components - 1 of 2
1 - Inflatable Restraint Seat Belt Tension Sensor - Passenger 2 - Inflatable Restraint Seat Position
Sensor (SPS) - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant
Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information
Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System
Information
INFORMATION
Bulletin No.: 06-08-50-009F
Date: December 23, 2010
Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With
Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices
Models:
2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing
System
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories).
Concerns About Safety and Alterations to the Front Passenger Seat
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT
VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY
ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN
OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF
SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED.
The front passenger seat in many GM vehicles is equipped with a passenger sensing system that
will turn off the right front passenger's frontal airbag under certain conditions, such as when an
infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the
right front passenger's seat mounted side impact airbag. For the system to function properly,
sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger
sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers,
upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by
GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an
aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or
between the occupant and the seat fabric.
Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM
ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR
SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE
APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH
IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE
NECESSARY BY SUCH USE.
Many types of aftermarket accessories are available to customers, upfitting shops, and dealers.
Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat
heaters are installed under the seat fabric. Additionally, seat covers made of leather or other
materials may have different padding thickness installed that could prevent the Passenger Sensing
System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to
the seat cushion, as this may interfere with the operation of the Passenger Sensing System and
either prevent proper deployment of the passenger airbag or prevent proper suppression of the
passenger air bag.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant
Sensor > Component Information > Technical Service Bulletins > Page 933
Seat Occupant Sensor: Locations
Passenger Compartment/Roof Component Views
Passenger Seat Components - 2 of 2
1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence
System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant
Sensor > Component Information > Technical Service Bulletins > Page 934
Seat Occupant Sensor: Service and Repair
Inflatable Restraint Passenger Presence System Replacement - Front
Removal Procedure
Warning
Replace the passenger presence system as a complete assembly to prevent possible injury to the
occupant. The bladder, the pressure sensor, the seat cushion, and the control module are
assembled and calibrated as a unit. Using only some of the components in the service kit will
cause the passenger presence system to operate improperly.
1. Remove the seat cushion trim cover and pad. 2. Disconnect the electrical connectors. 3.
Remove the bolts that retain the electronic control unit (ECU) (1) from the bottom of the passenger
seat cushion frame. 4. Remove the pressure switch (2) from the bottom of the passenger seat
cushion frame.
5. Remove the push-in retainers (1) that hold the bladder to the seat cushion frame. 6. Remove the
inflatable restraint passenger presence system from the seat.
Installation Procedures
1. Install the inflatable restraint passenger presence system to the seat. 2. Install the push-in
retainers (1) that hold the bladder to the seat cushion frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant
Sensor > Component Information > Technical Service Bulletins > Page 935
3. Install the pressure sensor (2) to the bottom of the passenger seat cushion frame.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the bolts that retain the ECU (1) to the bottom the passenger seat cushion frame.
Tighten the bolts to 2 Nm (18 lb in).
5. Connect the electrical connectors. 6. Install the seat cushion trim cover and pad. 7. Re-zero the
inflatable restraint passenger presence system. Refer to Control Module References (See: Testing
and Inspection/Programming and
Relearning).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor
> Component Information > Locations
Seat Position Sensor: Locations
Passenger Compartment/Roof Component Views
Under the Driver Seat Components
1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1)
5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver
Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver
Passenger Seat Components - 1 of 2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor
> Component Information > Locations > Page 939
1 - Inflatable Restraint Seat Belt Tension Sensor - Passenger 2 - Inflatable Restraint Seat Position
Sensor (SPS) - Passenger
Under the Passenger Seat Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor
> Component Information > Locations > Page 940
1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor
(SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger
(KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1)
7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor
> Component Information > Locations > Page 941
Seat Position Sensor: Diagrams
Component Connector End Views
Inflatable Restraint Seat Position Sensor - Left
Inflatable Restraint Seat Position Sensor - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor
> Component Information > Locations > Page 942
Seat Position Sensor: Service and Repair
Inflatable Restraint Seat Position Sensor Replacement (Power Seat)
Removal Procedure
1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Body and
Frame/Seats/Service and Repair/Front Seat
Replacement - Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and
Repair/Split Bench Seat Replacement).
2. Ensure that the seat is in the full rear position.
3. Locate the seat position sensor (1) under the seat on the inside of the inner seat rail. 4.
Disconnect the electrical connector (3) from the seat position sensor (1). 5. Remove the 2 nuts (2)
that retain the seat position sensor to the seat rail. 6. Remove the seat position sensor from the
seat.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor
> Component Information > Locations > Page 943
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the seat position sensor (1) to the seat rail with 2 nuts (2).
Tighten the seat position sensor nuts to 9 Nm (79 lb in).
2. Connect the electrical connector (13) to the seat position sensor (1). 3. Install the seat in the
vehicle. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and
Repair/Front Seat Replacement
- Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split
Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations
Clutch Switch: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations > Page 948
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations > Page 949
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations > Page 950
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations > Page 951
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
This vehicle has two different types of ignition lock cylinders based on what type of steering column
the vehicle is equipped with. The electric power steering (EPS) option, usually found on 4 cylinder
models, and the non EPS, usually found on 6 cylinder models, use different ignition lock cylinder
designs.
Ignition Lock Cylinder
The ignition lock cylinder uses all 10 key cut positions, 1-10 when counting from the key head. The
tumbler orientations alternate in adjacent locations from side to side with 5 tumblers on each side.
Important: The ignition lock cylinder tumblers (1) are not self retaining and must be held in place if
the key is not fully inserted in the lock cylinder (2), or until the lock cylinder (2) is assembled into
the case assembly (5).
1. Hold the uncoded cylinder assembly (2) positioned so the side with the security plug (3) faces to
the left of the key head. 2. Insert one tumbler spring (7) into each of the 4 tumbler spring holes. 3.
The first tumbler (1) to be loaded will be key cut position 1, the first number in the key code. Install
this tumbler in the tumbler slot closest to the
head of the lock cylinder (2), the end where the key is inserted.
4. Advancing one tumbler slot at a time, install tumblers 3, 5, and 7 sequentially on the same side
as tumbler 1. 5. Turn the lock cylinder over and insert one tumbler spring (7) into each of the 4
tumbler spring holes on the opposite side of the lock cylinder. 6. Insert tumbler 2 into the tumbler
slot closest to the head of the lock cylinder (2), the end where the key is inserted. 7. Advancing one
tumbler slot at a time, install tumblers 4, 6, and 8 sequentially on the same side as tumbler 2. 8.
Check for correct tumbler loading by holding the tumblers (1) in position and inserting the correct
key into the lock cylinder. All tumblers (1)
should be flush with the housing of the lock cylinder.
9. Lightly lubricate the tumblers and small detent recessed areas the tumblers are in with GM
Super Lube GM P/N 12346241 or equivalent light
lithium grease.
10. Take the slide piece and insert into the rotor. Ensure "Front of Sliding Piece" is facing the front
face of the rotor. If the slide piece is installed
incorrectly, the key cannot insert into the rotor due to no access to the ramp.
11. Install the pivot pin into the actuator lever and install the actuator lever into the ignition lock
cylinder housing. Ensure that the actuator lever is
inside of the lock cylinder housing at the end close to key insertion opening. Actuator lever should
pivot on the pin against spring tension.
12. Insert the key into the coded lock cylinder (2) and hold the lock cylinder positioned so the side
with the security plug (3) faces to the left of the key
head.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 957
13. Hold the ignition lock housing positioned so the security plug actuator lever (3) also faces to the
right of the key head. 14. Push the exposed end of the security plug actuator lever (3) toward the
center of the lock cylinder housing (1) and hold it. Insert the coded lock
cylinder (2) with the key in it into the ignition lock cylinder housing (1) until the cap is flush with the
housing.
15. Rotate the keyed lock cylinder counterclockwise slightly until it stops and detents outward
slightly. The key should be able to be removed and the
lock cylinder should remain in the housing.
16. Install the retaining clip (1) onto the coded lock cylinder where it comes out of the back of the
lock cylinder housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 958
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Removal Procedure
1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition
Lock Cylinder Replacement). 2. Remove the multifunction turn signal switch housing. Refer to
Multifunction Turn Signal Switch Housing Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch
Housing Replacement).
3. Remove the shear bolt from the ignition lock cylinder case using a hammer and chisel. 4.
Remove the ignition lock cylinder case.
Installation Procedure
1. Install the ignition lock cylinder case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the ignition lock cylinder case bolt and tighten it until the head shears off. 3. Install the
multifunction turn signal switch. Refer to Multifunction Turn Signal Switch Housing Replacement
(See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch
Housing Replacement).
4. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock
Cylinder Replacement). 5. The passlock sensor is part of the ignition switch. If replacing the ignition
switch, a passlock relearn will be needed. Refer to Control Module
References (See: Testing and Inspection/Programming and Relearning).
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Removal Procedure
1. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
2. Turn the ignition lock cylinder to the accessory position. 3. Insert the 90 degree tip of a pick type
tool into the ignition lock cylinder access hole. 4. Push and hold the ignition lock cylinder retaining
pin down.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 959
5. Pull the ignition lock cylinder away from the steering column.
Installation Procedure
1. Install the ignition lock cylinder by performing the following procedure:
1. Turn the ignition lock cylinder to the accessory position. 2. Push the ignition lock cylinder in until
the retaining pin locks it in place.
2. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Diagrams
Steering Angle Sensor: Diagrams
Component Connector End Views
Steering Wheel Position Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft
Lower Bearing Replacement
Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 967
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering
Steering Wheel Position Sensor Centering
Removal Procedure
Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE
removing the sensor from the steering column. Once you have identified the steering wheel
position sensor, follow the instructions listed in the removal procedure.
1. Verify the type of steering wheel position sensor.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right.
Important: If reusing the existing sensor, you do not have to align the sensor before removal.
Centering is not required when it is time to reinstall.
3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing
assembly. 5. To install the sensor, proceed to step 1 in the installation section.
6. From the technicians point of view, the FRONT of the sensor will have:
* A foam ring (2)
* A pin hole (1) for centering the pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff
(3) before removing the sensor. Failure to do so will cause misalignment when installing the
sensor. A new sensor will be required if misaligned.
7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the
sensor. 9. Remove the sensor from the adapter and bearing assembly.
10. To install the sensor, proceed to step 5 in the installation procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 968
11. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note the location of the pin hole.
12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing
assembly. 14. To install the sensor, proceed to step 9 in the installation procedure.
15. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note location of the pin hole.
* A sensor clip in FRONT of the sensor
16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18.
Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to
step 13 in the installation procedure.
20. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (3)
* A pin hole (1) for the centering pin-Note the location of the pin hole.
* An alignment mark (2) on the flush rotor flange cuff (3) for installation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 969
21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing
assembly. 23. To install the sensor, proceed to step 17 in the installation procedure.
24. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (4)
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* An alignment mark (3) on the flush rotor flange cuff (4) for installation
* A foam ring (1)
25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing
assembly. 27. To install the sensor, proceed to step 21 in the installation procedure.
Installation Procedure
Important: If reusing the existing sensor, no centering of the sensor is required.
1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin
until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1)
connector will be on your right.
From the technicians point of view, the BACK of the sensor (2) connector will be on your left.
3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 4. Install the connector to the sensor.
5. From the technicians point of view, the FRONT of the sensor will have:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 970
* A foam ring (4)
* A pin hole (7) for the centering pin-Note the location of the pin hole.
* A flushed rotor flange cuff (6)
* An alignment mark (5) for installation
6. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* A foam ring (3)
* An alignment tab (2) for installing into the adapter and bearing assembly
* A view of the inside of the connector
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 8. Install the connector to the sensor.
9. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A raised rotor flange cuff (5)
* An alignment mark (4) for installation
10. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 12. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 971
13. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A raised rotor flange cuff (4)
* An alignment mark (3) for installation
14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 16. Install the connector to the sensor.
17. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
* An alignment mark (3) for installation
18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 20. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 972
21. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A flush rotor flange cuff (5)
* An alignment mark (4) for installation
* A foam ring (6)
22. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 24. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams
Steering Angle Sensor: Diagrams
Component Connector End Views
Steering Wheel Position Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft
Lower Bearing Replacement
Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 979
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering
Steering Wheel Position Sensor Centering
Removal Procedure
Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE
removing the sensor from the steering column. Once you have identified the steering wheel
position sensor, follow the instructions listed in the removal procedure.
1. Verify the type of steering wheel position sensor.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right.
Important: If reusing the existing sensor, you do not have to align the sensor before removal.
Centering is not required when it is time to reinstall.
3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing
assembly. 5. To install the sensor, proceed to step 1 in the installation section.
6. From the technicians point of view, the FRONT of the sensor will have:
* A foam ring (2)
* A pin hole (1) for centering the pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff
(3) before removing the sensor. Failure to do so will cause misalignment when installing the
sensor. A new sensor will be required if misaligned.
7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the
sensor. 9. Remove the sensor from the adapter and bearing assembly.
10. To install the sensor, proceed to step 5 in the installation procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 980
11. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note the location of the pin hole.
12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing
assembly. 14. To install the sensor, proceed to step 9 in the installation procedure.
15. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note location of the pin hole.
* A sensor clip in FRONT of the sensor
16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18.
Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to
step 13 in the installation procedure.
20. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (3)
* A pin hole (1) for the centering pin-Note the location of the pin hole.
* An alignment mark (2) on the flush rotor flange cuff (3) for installation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 981
21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing
assembly. 23. To install the sensor, proceed to step 17 in the installation procedure.
24. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (4)
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* An alignment mark (3) on the flush rotor flange cuff (4) for installation
* A foam ring (1)
25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing
assembly. 27. To install the sensor, proceed to step 21 in the installation procedure.
Installation Procedure
Important: If reusing the existing sensor, no centering of the sensor is required.
1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin
until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1)
connector will be on your right.
From the technicians point of view, the BACK of the sensor (2) connector will be on your left.
3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 4. Install the connector to the sensor.
5. From the technicians point of view, the FRONT of the sensor will have:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 982
* A foam ring (4)
* A pin hole (7) for the centering pin-Note the location of the pin hole.
* A flushed rotor flange cuff (6)
* An alignment mark (5) for installation
6. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* A foam ring (3)
* An alignment tab (2) for installing into the adapter and bearing assembly
* A view of the inside of the connector
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 8. Install the connector to the sensor.
9. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A raised rotor flange cuff (5)
* An alignment mark (4) for installation
10. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 12. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 983
13. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A raised rotor flange cuff (4)
* An alignment mark (3) for installation
14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 16. Install the connector to the sensor.
17. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
* An alignment mark (3) for installation
18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 20. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 984
21. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A flush rotor flange cuff (5)
* An alignment mark (4) for installation
* A foam ring (6)
22. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 24. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 990
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 991
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 992
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 993
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 994
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Indicator Sensor Replacement
Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the
vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and
Tires/Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See:
Maintenance/Wheels and Tires/Tires/Service and
Repair/Removal and Replacement).
Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the
inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Indicator Sensor Replacement > Page 997
Tighten the sensor nut to 7 Nm (62 lb in).
Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting.
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels
and Tires/Tires/Service and Repair/Removal
and Replacement).
Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor
unique identification code cannot be learned into the body control module (BCM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensors internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Maintenance/Wheels and Tires/Service
and Repair).
6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor
Learn (See: Instrument Panel, Gauges and Warning Indicators/Tire
Monitoring System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Indicator Sensor Replacement > Page 998
Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement
Tire Valve Stem Grommet Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the
vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and
Tires/Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting:
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead
from the wheel.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the outside of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See:
Maintenance/Wheels and Tires/Tires/Service and
Repair/Removal and Replacement).
Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure
Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all
residual liquid sealant from the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the
sensor grommet from the valve stem.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor
valve stem.
3. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Indicator Sensor Replacement > Page 999
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 Nm (62 lb in).
Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels
and Tires/Tires/Service and Repair/Removal
and Replacement).
6. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Maintenance/Wheels and Tires/Service
and Repair).
7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations
Fluid Pressure Sensor/Switch: Locations
Powertrain Component Views
Inside the Transmission Components (M30)
36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift
Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid
Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC)
Pulse Width Modulation (PWM) Solenoid Valve
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1005
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (M30)
Description Location
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations
Transmission Position Switch/Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Left Side of the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1009
1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1010
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1011
Transmission Position Switch/Sensor: Diagrams
Component Connector End Views
Park/Neutral Position (PNP) Switch (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1012
Transmission Position Switch/Sensor: Service and Repair
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
2. Remove the following parts: (89), (92), (88), (85) and (84)
3. Remove the manual shaft seal (82) with a screwdriver.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1013
1. Inspect the following items:
* Manual shaft (84) for damage or burrs
* Parking lock actuator assembly (85) for damage
* Manual shift detent lever with shaft position switch assembly (88) for damage or cracks
* Manual valve link (89) for damage
* Manual shift detent lever pin (92) discard - Do NOT reuse.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the following items:
* Manual shift detent lever with shaft position switch assembly (88)
* Parking lock actuator assembly (85)
* Manual shaft (84) (model dependent)
* NEW manual shift detent lever pin (92)
* Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft).
3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams
Transmission Speed Sensor: Diagrams
Component Connector End Views
Automatic Transmission Input Shaft Speed (ISS) Sensor (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams
Clutch Pedal Position Sensor / Switch: Diagrams
Component Connector End Views
Clutch Pedal Position (CPP) Sensor (MA5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 1024
Clutch Pedal Position Sensor / Switch: Service and Repair
Clutch Pedal Position Switch Replacement
Removal Procedure
1. Disconnect the electrical connector (2) from the clutch pedal position switch (1).
2. Push the clutch pedal position switch retaining plate locking tabs (2) inward toward each other to
release. 3. Remove the clutch pedal position switch (3) from the clutch pedal assembly (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 1025
1. Slide the clutch pedal position switch (3) with retaining plate (2) into the clutch pedal bracket (1),
until the locking tabs (2) are fully engaged.
2. Connect the electrical connector (2) to the clutch pedal position switch (1). 3. Complete the
following in order to adjust the clutch pedal position switch (1).
1. Push the switch fully into the bracket, allowing the switch to ratchet in the retaining plate. 2.
Depress the clutch pedal all the way to the floor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Harness Routing Views
Power Window Switch: Locations Harness Routing Views
Harness Routing Views
Driver Door Harness Routing
1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside
Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body
Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver
Front Passenger Door Harness Routing
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Harness Routing Views > Page 1031
1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front
Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body
Harness) 9 - X210 (Body Harness to Front Passenger Door Harness)
Right Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Harness Routing Views > Page 1032
1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock
Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door
Harness)
Left Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Harness Routing Views > Page 1033
1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness
to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Harness Routing Views > Page 1034
Power Window Switch: Locations Door Component Views
Door Component Views
Driver Door Components
1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker
- Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch
(DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF)
Front Passenger Door Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Harness Routing Views > Page 1035
1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door
Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210
Left Rear Door Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Harness Routing Views > Page 1036
1 - Speaker - Left Rear 2 - Window Switch - Left Rear (A31) 3 - X316 4 - Window Motor - Left Rear
(A31) 5 - Door Lock Actuator - Left Rear (AU3)
Right Rear Door Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Harness Routing Views > Page 1037
1 - Window Switch - Right Rear (A31) 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right
Rear (AU3) 4 - Window Motor - Right Rear (A31) 5 - X317
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Page 1038
Power Window Switch: Diagrams
Component Connector End Views
Door Lock/Window Switch - Driver X1 (A31/AU3)
Door Lock/Window Switch - Driver X2 (A31/AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Page 1039
Door Lock/Window Switch - Passenger (A31/AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Page 1040
Window Switch - Left Rear (Crew Cab with A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Page 1041
Window Switch - Right Rear (Crew Cab with A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Page 1042
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side
Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Left
Side
Front Side Door Window Switch Replacement - Left Side
Removal Procedure
1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the front
of the switch plate up to disengage clip. 3. Remove the switch plate out of the door trim panel
opening.
4. Disconnect the electrical connectors (3, 4) from the switches (2, 5). 5. Remove the switch plate
assembly (1) from the vehicle. 6. If replacing only the switches, remove the switches from the plate.
7. If replacing only the switch plate, retain the switches for transfer.
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Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page
1045
Installation Procedure
1. Install the switches (2, 5) to the switch plate (1). 2. Connect the electrical connectors (3, 4) to the
switches (2, 5).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the switch plate assembly to the door trim panel with the 2 screws and tighten to 2 Nm (18
lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page
1046
Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Right
Side
Front Side Door Window Switch Replacement - Right Side
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page
1047
Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement
Rear Side Door Window Switch Replacement
Removal Procedure
1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the switch
plate up and out of the door trim panel.
3. Disconnect the electrical connectors from the switch module. 4. Remove the switch plate
assembly from the vehicle. 5. If replacing only the switch module, remove the module from the
switch plate. 6. If replacing only the switch plate, retain the switch module for transfer.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page
1048
1. Install the switch module to the switch plate. 2. Connect the electrical connector to the switch
module.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the rear switch plate assembly to the door trim panel with the 2 screws and tighten to 2
Nm (18 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications
Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications
WARRANTY ADMINISTRATION
Bulletin No.: 05-03-07-009C
Date: December 09, 2010
Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks
Supercede: This bulletin is being extensively revised to provide technicians and warranty
administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF
WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT
SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension).
Purpose
The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors'
warranty service requirements and recommendations for customer concerns related to wheel
alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel
Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty
service.
Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING
YOUR NEXT GM WHEEL ALIGNMENT SERVICE.
The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a
successful wheel alignment service.
1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension
and steering configurations. Vehicles
modified in any of these areas are not covered for wheel alignment warranty.
2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is
within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for
labor operations E2000 and E2020.
The following information must be documented or attached to the repair order:
- Customer concern in detail
- What corrected the customer concern?
- If a wheel alignment is performed:
- Consult SI for proper specifications.
- Document the "Before" AND "After" wheel alignment measurements/settings.
- Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin)
5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the
appropriate calibration maintenance schedules.
Important If it is determined that a wheel alignment is necessary under warranty, use the proper
labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel
Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for
other component repairs is to be charged to the component that causes a wheel alignment
operation.).
The following flowchart is to help summarize the information detailed in this bulletin and should be
used whenever a wheel alignment is performed.
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Verify Original Equipment Condition of the Vehicle
- Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are
on the vehicle.
- Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have
NOT been done to the vehicle.
- Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision
damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles,
suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact.
- Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving
may show up by looking at the tires and condition of the vehicle.
- Check for other additional equipment items that may significantly affect vehicle mass such as
large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in
trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and
wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed
semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of
these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with
equipment such as the above.)
Customer Concerns, "Normal Operation" Conditions and "Mileage Policy"
Possible Concerns
The following are typical conditions that may require wheel alignment warranty service:
1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of
effort required at the steering wheel to maintain the
vehicle's straight heading."
Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle
Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull
concerns can be due to road crown or road slope, tires, wheel alignment or even in rare
circumstances a steering gear issue. Lead/pull concerns due to road crown are considered
"Normal Operation" and are NOT a warrantable condition -- the customer should be advised that
this is "Normal Operation."
Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a
level condition. If so, this is more likely a "steering wheel angle" concern because the customer is
"steering" the vehicle to obtain a "level" steering wheel.
2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined
as the steering wheel angle (clocking)
deviation from "level" while maintaining a straight heading on a typical straight road.
3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the
shoulders of tires is NOT considered unusual and
should even out with a tire rotation; if the customer is concerned about a "feathering" condition of
the tires, the customer could be advised to rotate the tires earlier than the next scheduled
mileage/maintenance interval (but no later than the next interval). Be sure to understand the
customer's driving habits as this will also heavily influence the tire wear performance; tire wear from
aggressive or abusive driving habits is NOT a warrantable condition.
Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is
"normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can
show evidence of feathering from the factory. These issues do NOT affect the overall performance
and tread life of the tire. Dealer personnel should always check the customer's maintenance
records to ensure that tire inflation pressure is being maintained to placard and that the tires are
being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be
performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below.
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Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center
Ribs
Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder
Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear
Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear
Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the
repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center
wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF,
LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life,
etc. A field product report with pictures of the tire wear condition is recommended. Refer to
Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C.
4. Other repairs that affect wheel alignment; e.g., certain component replacement such as
suspension control arm replacement, engine cradle
adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock,
steering knuckle, etc. may require a wheel alignment.
Important If other components or repairs are identified as affecting the wheel alignment, policy calls
for the wheel alignment labor time to be charged to the replaced/repaired component's labor
operation time rather than the wheel alignment labor operations.
Important Vibration type customer concerns are generally NOT due to wheel alignment except in
the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are
NOT to be performed as an investigation/correction for vibration concerns.
"Normal Operation" Conditions
Vehicle Lead/Pull Due to Road Crown or Slope:
As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope.
Be sure to verify from the customer the types of roads they are driving as they may not recognize
the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires
significant steering effort to prevent it from "climbing" the road crown there may be an issue to be
looked into further.
Important
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A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within
"Normal Operation."
Mileage Policy
The following mileage policy applies for E2020 and E2000 labor operations: Note
Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana
Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing
the vehicles.
- 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to
the tie down during shipping, the vehicle's suspension requires some time to reach normal
operating position. For this reason, new vehicles are generally NOT to be aligned until they have
accumulated at least 800 km (500 mi). A field product report should accompany any claim within
this mileage range.
- 801-12,000 km (501-7,500 mi):
- If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle
steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be
apparent early in the life of the vehicle. The following policy applies:
- Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT,
Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and
Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required
- All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above:
E2000/E2020 Claims: Dealer Service Manager Authorization Required
- 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible
for the wheel alignment expense or dealers may provide on a case-by case basis a one-time
customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component
required the use of the subject labor operations, the identified defective component labor operation
will include the appropriate labor time for a wheel alignment as an add condition to the component
repair.
Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN.
Warranty Documentation Requirements
When a wheel alignment service has been deemed necessary, the following items will need to be
clearly documented on/with the repair order:
- Customer concern in detail
- What corrected the customer concern?
- If a wheel alignment is performed:
- Consult SI for proper specifications.
- Document the "Before" AND "After" wheel alignment measurements/settings.
- Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin)
1. Document the customer concern in as much detail as possible on the repair order and in the
warranty administration system. Preferred examples:
- Steering wheel is off angle in the counterclockwise direction by approximately x degrees or
clocking position.
- Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe,
Moderate or Slight.
- RF and LF tires are wearing on the outside shoulders with severe feathering.
Important In the event of a lead/pull or steering wheel angle concern, please note the direction of
lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the
repair order and within the warranty claim verbatim.
Important In the event of a tire wear concern, please note the position on the vehicle and where the
wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder.
2. Document the technician's findings on cause and correction of the issue. Examples:
- Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees
to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees.
- Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of
+0.30 degrees to 0.00 degrees on the vehicle.
- Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees.
3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the
Repair Order or if print-out capability is not
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Steering/Suspension - Wheel Alignment Specifications > Page 1057
available, measurements may also be clearly and legibly handwritten into the Wheel Alignment
Repair Order Questionnaire attached to this bulletin.
4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of
"Before" and "After" wheel alignment measurements to
the Repair Order and retain for use by GM.
Wheel Alignment Equipment and Process
Wheel alignments must be performed with a quality machine that will give accurate results when
performing checks. "External Reference" (image-based camera technology) is preferred. Please
refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment
Requirements and Recommendations.
Requirements:
- Computerized four wheel alignment system.
- Computer capable of printing before and after alignment reports.
- Computer capable of time and date stamp printout.
- Racking system must have jacking capability
- Racking system must be capable of level to 1.6 mm (1/16 in)
- Appropriate wheel stops and safety certification
- Built-in turn plates and slip plates
- Wheel clamps capable of attaching to 20" or larger wheels
- Racking capable of accepting any GM passenger car or light duty truck
- Operator properly trained and ASE-certified (U.S. only) in wheel alignment
Recommendations:
Racking should have front and rear jacking capability.
Equipment Maintenance and Calibration:
Alignment machines must be regularly calibrated in order to give correct information. Most
manufacturers recommend the following:
- Alignment machines with "internal reference" sensors should be checked (and calibrated, if
necessary) every six months.
- Alignment machines with "external reference" (image-based camera technology) should be
checked (and calibrated, if necessary) once a year.
- Racks must be kept level to within 1.6 mm (1/16 in).
- If any instrument that is part of the alignment machine is dropped or damaged in some way,
check the calibration immediately.
Check with the manufacturer of your specific equipment for their recommended service/calibration
schedule.
Wheel Alignment Process
When performing wheel alignment measurement and/or adjustment, the following steps should be
taken:
Preliminary Steps:
1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels
and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4.
Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for
looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to
stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate
for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI).
Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the
wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the
specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads,
such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's
instructions.
Measure/Adjust:
Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify
that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date
by comparing these to the wheel alignment specifications for the appropriate model and model year
in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments,
irregular and/or premature tire wear and repeat customer concerns
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Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear
wheel alignment angles first in order to obtain proper front wheel alignment angles.
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front
and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment
angles and record the readings.
If necessary, adjust the wheel alignment to vehicle specification and record the before and after
measurements. Refer to Wheel Alignment Specifications in SI.
Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only
source of GM wheel alignment specifications that is kept up-to-date throughout the year.
Test drive vehicle to ensure proper repair.
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Frame Angle Measurement (Express / Savana Only) ........
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What corrected the customer concern and was the repair verified?
Please Explain: .............
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Fastener Tightening
Specifications
Alignment: Specifications Fastener Tightening Specifications
Fastener Tightening Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Fastener Tightening
Specifications > Page 1063
Alignment: Specifications Trim Height Specifications
Trim Height Specifications
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Alignment: Specifications Wheel Alignment Specifications
Wheel Alignment Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster
Description
Alignment: Description and Operation Caster Description
Caster Description
Caster is the tilting of the uppermost point of the steering axis either forward or backward, when
viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-).
Caster influences directional control of the steering but does not affect the tire wear. Caster is
affected by the vehicle height, therefore it is important to keep the body at its designed height.
Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the
vehicle is lower than its designated trim height, the front suspension moves to a more positive
caster. If the rear of the vehicle is higher than its designated trim height, the front suspension
moves to a less positive caster.
With too little positive caster, steering may be touchy at high speed and wheel returnability may be
diminished when coming out of a turn. If one wheel has more positive caster than the other, that
wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead
to the side with the least amount of positive caster.
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Alignment: Description and Operation Camber Description
Camber Description
Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle.
When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at
the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical.
Camber settings influence the directional control and the tire wear.
Too much positive camber will result in premature wear on the outside of the tire and cause
excessive wear on the suspension parts.
Too much negative camber will result in premature wear on the inside of the tire and cause
excessive wear on the suspension parts.
Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side
with the most positive camber.
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Alignment: Description and Operation Toe Description
Toe Description
Toe is a measurement of how much the front and/or rear wheels are turned in or out from a
straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the wheels roll parallel.
Toe also offsets the small deflections of the wheel support system that occur when the vehicle is
rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the
wheels tend to roll parallel on the road when the vehicle is moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.
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Alignment: Description and Operation Setback Description
Setback Description
Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may
be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The
first clue is a caster difference from side-to-side of more than 1 degree.
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Alignment: Description and Operation
Caster Description
Caster Description
Caster is the tilting of the uppermost point of the steering axis either forward or backward, when
viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-).
Caster influences directional control of the steering but does not affect the tire wear. Caster is
affected by the vehicle height, therefore it is important to keep the body at its designed height.
Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the
vehicle is lower than its designated trim height, the front suspension moves to a more positive
caster. If the rear of the vehicle is higher than its designated trim height, the front suspension
moves to a less positive caster.
With too little positive caster, steering may be touchy at high speed and wheel returnability may be
diminished when coming out of a turn. If one wheel has more positive caster than the other, that
wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead
to the side with the least amount of positive caster.
Camber Description
Camber Description
Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle.
When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at
the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical.
Camber settings influence the directional control and the tire wear.
Too much positive camber will result in premature wear on the outside of the tire and cause
excessive wear on the suspension parts.
Too much negative camber will result in premature wear on the inside of the tire and cause
excessive wear on the suspension parts.
Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side
with the most positive camber.
Toe Description
Toe Description
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Toe is a measurement of how much the front and/or rear wheels are turned in or out from a
straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the wheels roll parallel.
Toe also offsets the small deflections of the wheel support system that occur when the vehicle is
rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the
wheels tend to roll parallel on the road when the vehicle is moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.
Setback Description
Setback Description
Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may
be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The
first clue is a caster difference from side-to-side of more than 1 degree.
Thrust Angles Description
Thrust Angles Description
The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action
relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the
thrust angle is geometrically aligned with the body centerline (2).
In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The
resulting deviation from the centerline is the thrust angle.
Lead/Pull Description
Lead/Pull Description
At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at
the steering wheel to maintain the vehicle's straight
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path.
Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal
operation.
Lead/pull is usually caused by the following factors:
* Road slope
* Variability in tire construction
* Wheel alignment (front cross caster and camber)
* Unbalanced steering gear
* Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if
equipped.
Wander Description
Wander Description
Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with
hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external
disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel.
Scrub Radius Description
Scrub Radius Description
Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the
tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the
SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle
to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller
the scrub radius, the better the directional stability. Installing aftermarket wheels that have
additional offset will dramatically increase the scrub radius. The newly installed wheels may cause
the centerline of the tires to move further away from the spindle. This will increase the scrub radius.
A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive
vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub
radius is not directly measurable by the conventional methods. Scrub radius is projected
geometrically by engineers during the design phase of the suspension.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1073
Alignment: Testing and Inspection
Trim Height Inspection
Trim Height Measurements
Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights
can cause bottoming out over bumps, damage to the suspension components and symptoms
similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns
and before checking the wheel alignment. Perform the following before measuring the trim heights.
1. Make sure that the vehicle is on a level surface, such as an alignment rack. 2. Remove the
alignment rack floating pins. 3. Set the tire pressure to the pressures shown on the certification
label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID
Label (See: Application and ID).
4. Check the fuel level. Add additional weight if necessary to simulate a full tank. 5. Make sure that
the rear compartment is empty except for the spare tire. 6. Close the doors and he hood.
Z Height Measurement
The Z height dimension measurement determines the proper ride height for the front end of the
vehicle. Vehicles equipped with torsion bars use an adjusting arm in order to adjust the Z height
dimension. Vehicles without torsion bars have no adjustment and could require replacement of
suspension components. Jounce the front and rear suspension to obtain at least 38 mm (1.5 in)
deflection, then allow the vehicle to settle.
Important: The left and right Z height difference should be no more than 12 mm (0.47 in).
1. Set the top edge of the level on the reference surface (Point A) of the steering knuckle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1074
2. With the level on the steering knuckle (C), extend the level directly under the rear of the rear of
the front attachment bolt of the lower control arm
(A).
3. While keeping the level in contact with the knuckle reference surface, adjust the level up or down
until the bubble indicates it is horizontally level. 4. Extend a tape measure straight down from the
center of the attachment bolt. The point where the tape measure and the level intersect is your first
measurement.
5. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the
level directly under the front end of the rear
attachment bolt of the lower control arm (B).
6. Extend a tape measure straight down from the center of the attachment bolt. The point where
the tape measure and the level intersect is your
second measurement.
7. Average the 2 readings (add them together, and then divide by 3) and this result is your final Z
height number. 8. Repeat steps 1 through 7, a total of 3 times, writing down the results. 9. Average
the results (add them together, and then divide by 3) and this result is your final Z height number.
10. Compare your Z height number with the Service Information Z height specification. Refer to
Trim Height Specifications (See:
Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height
Specifications).
Z Height Adjustment
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1075
1. For vehicles equipped with a torsion bar suspension turn the torsion bar adjuster bolt (1)
clockwise to raise the and counterclockwise to lower the
height adjustment.
2. For vehicles without torsion bars, replace damaged or worn components as necessary.
D Height Measurement
Important: The left and right D height difference should be no more than 12 mm (0.47 in.)
1. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let
the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. D Height shall be
measured as the perpendicular distance from the inside lip of the jounce bumper cup flange to the
jounce bumper contact pad, or
top of the rear axle "tube" when a jounce bumper pad is not used.
5. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 6. Gently remove your hands and let
the vehicle settle. 7. Repeat this operation 2 more times for a total of 3 times. 8. Re-measure the D
height as in step 4. 9. The true D height is the average of the measurement from step 4 and step 8.
Refer to Trim Height Specifications (See: Specifications/Mechanical
Specifications/Suspension/System Specifications/Trim Height Specifications).
10. If these measurements are out of specifications, inspect for the following conditions:
* Worn or damaged suspension components
* Collision damage
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement
Alignment: Service and Repair Wheel Alignment Measurement
Wheel Alignment Measurement
Steering and vibration complaints are not always the result of improper alignment. One possible
cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly
manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical
straight road, lead/pull is the amount of effort required at the steering wheel to maintain the
vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without
pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and
Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull
Correction) in order to determine if the vehicle has a tire lead problem.
Before performing any adjustment affecting wheel alignment, perform the following inspections and
adjustments in order to ensure correct alignment readings:
* Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire
Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID) and Tire Diagnosis Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related
Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear).
* Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications
(See: Testing and Inspection/Symptom Related Diagnostic Procedures/Vibration Diagnosis and
Correction/Specifications/Tire and Wheel Runout Specifications).
* Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis
(See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General
Diagnostics/Wheel Bearings Diagnosis).
* Inspect the ball joints for looseness or wear.
* Inspect the tie rod ends for looseness or wear.
* Inspect the control arms and stabilizer shaft for looseness or wear.
* Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications
(See: Steering and Suspension/Steering/Specifications).
* Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to
Suspension Strut and Shock Absorber Testing - On Vehicle (See: Steering and
Suspension/Suspension/Testing and Inspection/Component Tests and General
Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle).
* Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Steering and
Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim
Height Inspection).
* Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or
suspension components.
* Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load
added.
Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in
the vehicle, these items should remain in the vehicle during alignment adjustments. Give
consideration also to the condition of the equipment being used for the alignment. Follow the
equipment manufacturer's instructions.
Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the
setting exceeds the service allowable specifications, correct the alignment to the service preferred
specifications. Refer to Wheel Alignment Specifications (See: Specifications).
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front
and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment
angles and record the readings.
Note: *
Record the "Before" and "After" alignment measurements.
* When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel
alignment angles first in order to obtain proper front alignment angles.
4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment
Specifications (See: Specifications).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 1078
Alignment: Service and Repair Front Caster and Camber Adjustment
Front Caster and Camber Adjustment
Special Tools
J 45938 Alignment Socket
1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the
slotted frame bracket in order to reposition the
control arm. Note: Before adjusting the caster and camber angles, jounce the front bumper three
times to allow the vehicle to return to normal height.
Measure and adjust the caster and the camber with the vehicle at curb height. The front
suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Specifications (See:
Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height
Specifications).
For an accurate reading, do not push or pull on the tires during the alignment process.
2. Determine the caster angle (2). Be sure to compensate for frame angle where required.
3. Determine the positive camber (2) or negative camber (3) angle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 1079
4. The 4WD and 2WD Z71 vehicles are adjusted at the upper control arm.
5. The 2WD vehicles are adjusted at the lower control arm. 6. Remove the pinned adjusting cam
insert. Do not reinstall the cam insert. 7. Loosen the control arm cam adjustment bolts.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
8. Using the J 45938 adjust the caster and the camber angle by turning the cam bolts until the
specifications have been met.
When the adjustments are complete, hold the cam bolt in order to ensure the cam bolt position
does not change while tightening the nut.
* Tighten the 2WD cam nuts to 155 Nm (114 lb ft).
* Tighten the 4WD cam nuts to 155 Nm (114 lb ft).
9. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment
Specifications (See: Specifications).
When the caster and camber are within specifications, adjust the toe. Refer to Wheel Alignment Steering Wheel Angle and/or Front Toe Adjustment (See: Wheel Alignment - Steering Wheel Angle
and/or Front Toe Adjustment).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 1080
Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe
Adjustment
Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment
1. Loosen the jam nut on the tie rod. 2. Rotate the inner tie rod to the required toe specification
setting. Refer to Wheel Alignment Specifications (See: Specifications).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the jam nut on the tie rod to 70 Nm (52 lb ft). 4. Check the toe setting after tightening. 5.
Re-adjust the toe setting if necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Page 1081
Alignment: Tools and Equipment
Special Tools
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications
Fuel Pressure: Specifications
Fuel pressure (Ignition ON, engine OFF).............................................................................................
..............................................345-414 kPa (50-60 psi) fuel pressure should not decrease more than
34 kPa (5 psi) in 1 minute
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications > Page 1086
Fuel Pressure: Service Precautions
Relieving Fuel Pressure Warning
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications > Page 1087
Fuel Pressure: Testing and Inspection
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category.
Circuit/System Description
The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when
the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for
2 seconds unless the engine is in Crank or Run. While this voltage is being received, the FPCM
closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump
module in order to maintain the desired fuel rail pressure.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel
pump module, eliminating the need for a return pipe from the engine. A returnless fuel system
reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the
fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.
The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump
module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and
the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of the
flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump
located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel
pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the
correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow
check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed
pipe and the fuel rail in order to prevent long cranking times.
Electrical Information Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning)for scan
tool information Special Tools
* CH 48027 - Fuel Pressure Gage
* J 37287 - Fuel Line Shut-Off Adapters
Circuit/System Verification
Note: *
Inspect the fuel system for damage or external leaks before proceeding.
* Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
1. Ignition OFF, all accessories OFF, install the CH 48027 - Gage. Refer to Fuel Pressure Gage
Installation and Removal (See: Fuel Filter/Fuel
Pressure Release/Service and Repair/Fuel Pressure Gage Installation and Removal).
2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is
between 345-414 kPa (50-60 psi) and remains steady
for 5 minutes.
Circuit/System Testing
Note: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure
gage while the fuel pump is operating. Verify the
fuel pressure is between 345-414 kPa (50-60 psi).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications > Page 1088
‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel
pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the
items listed below. If all items test
normal, replace the fuel pump.
* Restricted fuel feed pipe
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
Note: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump
stops operating, the fuel pressure should stabilize and remain constant.
2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
‹› If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See:
Fuel Filter/Fuel Pressure Release/Service and
Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)).
2. Install the J 37287 - Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the
valve on the J 37287 - Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a
scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 Shut-Off Adapters. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1
minute.
‹› If the fuel pressure drops, locate and replace the leaking fuel injector.
7. If the fuel system test normal, replace the fuel pump.
3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
‹› If the fuel pressure decreases more than the specified value, replace the fuel pump.
4. Operate the vehicle within the Conditions of the customer's concern while monitoring the fuel
pressure with the CH 48027 - Gage. The fuel
pressure should not drop off during acceleration, cruise or hard cornering.
‹› If the fuel pressure drops off, test, inspect and repair the items listed below. If all items test
normal, replace the fuel sender.
* Restricted fuel feed pipe
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Powertrain
Management/Computers and Control Systems/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls).
Repair Instructions
Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Verification Tests and Procedures) after completing the diagnostic procedure.
* Fuel Hose/Pipes Replacement - Chassis (See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Return Line/Service and Repair)
* Fuel Injector Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel
Injector/Service and Repair/Removal and Replacement)
* Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Pump/Service and Repair)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air
Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Resonator Outlet Duct Replacement
Removal Procedure
1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement
(See: Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct.
3. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air
Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1093
4. Loosen the air cleaner outlet duct clamp (1) at the throttle body. 5. Grasp the air cleaner outlet
duct near the ball stud and firmly pull up in order to disengage the duct from the ball stud. 6.
Remove the air cleaner outlet duct (2) from the throttle body and the air cleaner housing.
Installation Procedure
1. Install the air cleaner outlet duct (2) to the throttle body and the air cleaner housing. 2. Ensure
that the air cleaner outlet duct tab rests over the ball stud, press down on the duct tab in order to
engage the duct to the ball stud.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the air cleaner outlet duct clamp (1) at the throttle body.
Tighten the clamp to 3.5 Nm (31 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air
Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1094
4. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing.
Tighten the clamp to 3.5 Nm (31 lb in).
5. Install the PCV line (1) to the air cleaner outlet duct. 6. Install the intake manifold cover. Refer to
Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Air Cleaner Fresh Air Duct/Hose/Service and
Repair).
2. Release the air cleaner upper housing retainer clips (1).
3. Open the air cleaner upper housing (1). 4. Remove the air filter element (2) from the lower air
cleaner housing. 5. Inspect the air cleaner assembly for debris or damage and repair as necessary.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 1098
1. Install the air filter element (2) to the lower air cleaner housing. 2. Close the air cleaner upper
housing (1).
3. Latch the air cleaner upper housing retainer clips (1). 4. Install the air cleaner outlet duct. Refer
to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service
and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning
(See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Fuses and Circuit Breakers/Fuse/Application and ID).
2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine
cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail
service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten
the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1104
Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel
Pressure Relief (With CH 48027))Fuel Pressure
Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)).
2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or
diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's
directions.
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1105
1. Relieve the fuel system pressure, if required. Perform the following steps:
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from
the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the
fuel rail service port cap. 6. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1106
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH-48027)
Special Tools
CH-48027 - Digital Pressure Gage
Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery
and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Fuses and Circuit Breakers/Fuse/Application and ID).
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1107
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT
necessary to proceed with the following steps.
12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4)
from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and
place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the
engine cover, if required. 17. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order: Specifications
Ignition System Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Testing and Inspection
Ignition Cable: Testing and Inspection
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to
accurately identify conditions that may affect engine operation. Inspect for the following conditions:
1. Correct routing of the spark plug wires - Incorrect routing may cause cross-firing. 2. Any signs of
cracks or splits in the wires. 3. Inspect each boot for the following conditions:
* Tearing
* Piercing
* Arcing
* Carbon tracking
* Corroded terminal
If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace
the wire and the component connected to the wire.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Testing and Inspection > Page 1114
Ignition Cable: Service and Repair
Spark Plug Wire Replacement
Removal Procedure
1. Remove the spark plug wire from the spark plug.
* Twist each spark plug 1/2 turn.
* Pull only on the boot in order to remove the wire from each spark plug.
2. Remove the spark plug wire from the ignition coil.
* Twist each spark plug boot 1/2 turn.
* Pull only on the boot in order to remove the wires from the ignition coil.
Installation Procedure
1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3.
Inspect the wires for proper installation:
* Push sideways on each boot in order to inspect the seating.
* Reinstall any loose boot.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition
System - Runs Rough MIL/ON DTC P0300/P0306
Spark Plug: Customer Interest Ignition System - Runs Rough MIL/ON DTC P0300/P0306
TECHNICAL
Bulletin No.: 09-06-04-025A
Date: December 20, 2010
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs
Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition
Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille)
Models:
2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER
H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to
GWM/IMH
Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification
section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion
System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) is illuminated.
Some customers may also comment that the engine runs rough.
The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as
current or in history, depending on which engine the vehicle is equipped with.
Upon further examination, the technician may observe evidence of water intrusion into the spark
plug recess area.
Cause
This condition may be caused by an engine being exposed to a large quantity of water, which may
result in some of the water seeping down past the vented threads of an ignition coil bolt, then
flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole,
and collecting in the spark plug recess area.
Correction
Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If
evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the
appropriate DTC procedures in SI.
1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the
affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner
Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical
connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove
the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil
Replacement in SI.
Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply
Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads.
5. Inspect for water intrusion in the spark plug recess areas.
Warning
Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
6. If any water is present, then remove the water from the spark plug recess areas with low
pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug
Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed
into the cylinder head. Refer to Spark Plug Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition
System - Runs Rough MIL/ON DTC P0300/P0306 > Page 1123
9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as
indicated in the illustration, and apply it to the
ignition coil bolt threads also.
10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition
Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition
coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet
duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a
scan tool.
Hood Grille Modification for HUMMER H3 Vehicles Only
Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall
#10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall
#10088A has been performed on the vehicle, DO NOT perform the following hood grille
modification.
1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille
Replacement (H3T) in SI.
2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention
clip (1) opening in the vehicle hood (all 4
sides of the rectangular slot).
3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly
against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement
(H3T) in SI.
5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme
water pressure should not be directly applied to the
edges of the hood air grille.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition
System - Runs Rough MIL/ON DTC P0300/P0306 > Page 1124
from other sources.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 >
Ignition System - Runs Rough MIL/ON DTC P0300/P0306
Spark Plug: All Technical Service Bulletins Ignition System - Runs Rough MIL/ON DTC
P0300/P0306
TECHNICAL
Bulletin No.: 09-06-04-025A
Date: December 20, 2010
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs
Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition
Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille)
Models:
2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER
H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to
GWM/IMH
Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification
section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion
System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) is illuminated.
Some customers may also comment that the engine runs rough.
The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as
current or in history, depending on which engine the vehicle is equipped with.
Upon further examination, the technician may observe evidence of water intrusion into the spark
plug recess area.
Cause
This condition may be caused by an engine being exposed to a large quantity of water, which may
result in some of the water seeping down past the vented threads of an ignition coil bolt, then
flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole,
and collecting in the spark plug recess area.
Correction
Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If
evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the
appropriate DTC procedures in SI.
1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the
affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner
Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical
connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove
the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil
Replacement in SI.
Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply
Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads.
5. Inspect for water intrusion in the spark plug recess areas.
Warning
Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
6. If any water is present, then remove the water from the spark plug recess areas with low
pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug
Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed
into the cylinder head. Refer to Spark Plug Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 >
Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 1130
9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as
indicated in the illustration, and apply it to the
ignition coil bolt threads also.
10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition
Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition
coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet
duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a
scan tool.
Hood Grille Modification for HUMMER H3 Vehicles Only
Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall
#10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall
#10088A has been performed on the vehicle, DO NOT perform the following hood grille
modification.
1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille
Replacement (H3T) in SI.
2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention
clip (1) opening in the vehicle hood (all 4
sides of the rectangular slot).
3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly
against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement
(H3T) in SI.
5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme
water pressure should not be directly applied to the
edges of the hood air grille.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 >
Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 1131
from other sources.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Page 1132
Spark Plug: Specifications
Ignition System Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Page 1133
Spark Plug: Application and ID
Ignition System Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Page 1134
Spark Plug: Testing and Inspection
Spark Plug Inspection
* Verify that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications ( See: Powertrain Management/Ignition
System/Specifications) for the correct spark plug.
* Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling - Colder plug
- Pre-ignition causing spark plug and/or engine damage - Hotter plug
* Inspect the terminal post (1) for damage.
- Inspect for a bent or broken terminal post (1)
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post should not
move.
* Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical
charge traveling across the insulator between the terminal post (1) and ground. Inspect for the
following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess are of the cylinder head for moisture, such as oil, coolant, or water.
A spark plug boot that is saturated will cause arcing to ground.
* Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack
instead of the electrodes (3,4).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Page 1135
* Inspect for evidence of improper arcing.
- Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition
System Specifications (See: Powertrain Management/Ignition System/Specifications). An
excessively wide electrode gap can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Powertrain
Management/Ignition System/Specifications). Insufficient torque can prevent correct spark plug
operation. An over torqued spark plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
* A rattling sound indicates internal damage.
* A looses center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3,4). Deposits on the electrodes (3,4) reduce or eliminates the
gap.
- Inspect for worn or missing platinum pads on the electrodes (3,4), if equipped.
- Inspect for excessive fouling.
* Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during installation.
Visual Inspection
* Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are
normal combustion by-products from fuels with additives.
* Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions:
- Rich fuel mixtures
* Leaking fuel injectors
* Excessive fuel pressure
* Restricted air filter element
* Incorrect combustion
- Reduced ignition system voltage output
* Weak ignition coils
* Worn ignition wires
* Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that
normal combustion deposits may not burn off.
* Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white
coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity
unless they form into a glazing over the electrode.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Page 1136
Spark Plug: Service and Repair
Spark Plug Replacement
Removal Procedure
1. Remove the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition
Cable/Service and Repair). 2. Loosen the spark plug 1-2 turns. 3. Brush or using compressed air,
blow away any dirt from around the spark plug. 4. Remove the spark plug.
If removing more than one plug, place each plug in a tray marked with the corresponding cylinder
number.
Installation Procedure
1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as
needed. Refer to Ignition System Specifications (See: Powertrain Management/Ignition
System/Specifications).
3. Hand start the spark plug in the corresponding cylinder.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Tighten the spark plug.
Tighten the plug to 20 Nm (15 lb ft).
5. Install the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition Cable/Service
and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
COMPRESSION CHECK
If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the
combustion chamber through the spark plug hole. Measure the compression again and record the
reading. The minimum compression in any 1 cylinder should not be less than 70 percent of the
highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest
pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other
cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1140
Compression Check: Testing and Inspection
Engine Compression Test
1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable
the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6.
Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression
gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the
compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject
approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark
plug
hole. Measure the compression again and record the reading.
10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690 kPa
(100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest
allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x
70% = 105).
* Normal - Compression builds up quickly and evenly to the specified compression for each
cylinder.
* Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the
following strokes, but does not reach normal. Compression improves considerably when you add
oil.
* Valves Leaking - Compression is low on the first stroke. Compression usually does not build up
on the following strokes. Compression does not improve much when you add oil.
* If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders
does not increase the compression, the cause may be a head gasket leaking between the
cylinders.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations
Timing Component Alignment Marks: Locations
Inspect the sprockets for proper alignment. The mark on the camshaft sprocket (1) should be
located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in
the 12 o'clock position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine
- Drive Belt Misalignment Diagnostics
Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics
INFORMATION
Bulletin No.: 08-06-01-008A
Date: July 27, 2009
Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of
Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt
Models:
2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 Vehicles 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add a model year and update the Tool Information.
Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine).
Background
Several aftermarket companies offer laser alignment tools for accessory drive systems that can be
very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges
from $160 - $200.
EN-49228 Laser Alignment Tool - Drive Belt
The GM Tool program has now made available a competitive, simple to use and time-saving laser
tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the
guesswork from proper pulley alignment and may serve to reduce comebacks from:
- Drive Belt Noise
- Accelerated Drive Belt Wear
- Drive Belt Slippage
Instructions
The instructions below are specific only to the truck Gen IV V-8 family of engines. These
instructions are only for illustrative purposes to show how the tool may be used. Universal
instructions are included in the box with the Laser Alignment Tool - Drive Belt.
Caution
- Do not look directly into the beam projected from the laser.
- Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses
help reduce laser beam glare in many circumstances.
- Always use laser safety glasses when using the laser. Laser safety glasses are not designed to
protect eyes from direct laser exposure.
1. Observe and mark the serpentine belt orientation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine
- Drive Belt Misalignment Diagnostics > Page 1148
2. Remove the serpentine belt from the accessory drive system.
3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves
of the pulley, farthest from the front of the
engine.
4. Install the retaining cord around the pulley and to the legs of the tool.
5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the
tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light
beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley
alignment.
- If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly.
- If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the
position of the power steering pulley as required.
- Refer to SI for Power Steering Pulley Removal and Installation procedures.
9. Install the serpentine belt to the accessory drive system in the original orientation.
10. Operate the vehicle and verify that the belt noise concern is no longer present.
Tool Information
Please visit the GM service tool website for pricing information or to place your order for this tool.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine
- Drive Belt Misalignment Diagnostics > Page 1149
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page
1150
Drive Belt: Service Precautions
Belt Dressing Caution
Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the
composition of the drive belt. Failure to follow this recommendation will damage the drive belt.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page
1151
Drive Belt: Description and Operation
Drive Belt System Description
The drive belt system consists of the following components:
* The drive belt
* The drive belt tensioner
* The drive belt idler pulley
* The crankshaft balancer pulley
* The accessory drive component mounting brackets
* The accessory drive components
- The power steering pump
- The generator
- The A/C compressor
- The engine cooling fan
- The water pump, if belt driven
The drive belt system may use 2 belts. The drive belt (1) is thin so that it can bend backwards and
has several ribs to match the grooves in the pulleys. The drive belts are made of different types of
rubbers - chloroprene or EPDM - and have different layers or plies containing either fiber cloth or
cords for reinforcement.
Both sides of the drive belt may be used to drive the different accessory drive components. When
the back side of the drive belt is used to drive a pulley, the pulley is smooth.
The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component
pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent
the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the
drive belt by the accessory drive components and the crankshaft.
The drive belt system has an idler pulley, which is used to add wrap to the adjacent pulleys.
A/C Compressor Drive Belt
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page
1152
The outward appearance of the belt (1) is similar to the current design serpentine belt. The
reinforcing cord provides its unique qualities. The belt cord is made of a polyamid material. The
polyamid cord is more elastic than the more traditional aramid or polyester cord designs. A
tensioner is not needed.
Polyamid cord, when combined with a more elastic backing compound, ensures the belt is able to
maintain the specified tension within the specified range of usage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis
Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Chirping, Squeal, and Whine Diagnosis
Diagnostic Aids
* A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It
may be necessary to spray a small amount of water on the drive belts in order to duplicate the
customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt
pulleys may be the probable solution.
* If the noise is intermittent, verify the accessory drive components by varying their loads making
sure they are operated to their maximum capacity. An overcharged A/C system, power steering
system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
* A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or
suspension component. Other items of the vehicle may also cause the noise.
* The drive belts will not cause a whine noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be
engine related. This step is to verify that the engine is making the noise. If the engine is not making
the noise do not proceed further with this table. 3. The noise may be an internal engine noise.
Removing the drive belts one at a time and operating the engine for a brief period will verify the
noise is related to the drive belt. When removing the drive belt the water pump may not be
operating and the engine may overheat. Also DTCs may set when the engine is operating with the
drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it
can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of
the pulleys may be caused from improper mounting of the accessory drive component, incorrect
installation of the accessory drive component pulley, or the pulley bent inward or outward from a
previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two
or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the
proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the
possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for
being bent should include inspecting for a dent or other damage to the pulleys that would prevent
the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a
pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the
drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper
belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal
noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt
tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be
routed properly and may be turning an accessory drive component in the wrong direction. 16.
Misalignment of the pulleys may be caused from improper mounting of the accessory drive
component, incorrect installation of the accessory drive component pulley, or the pulley bent inward
or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley
grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive
component for the proper installation procedure for that pulley. 17. This test is to verify that the
pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes.
19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a
temporary repair.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 1155
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 1156
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 1157
Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Vibration from the engine
operating may cause a body component or another part of the vehicle to make rumbling noise.
Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the
power steering system restricted or the incorrect fluid, or an extra load on the generator. To help
identify an intermittent or an improper condition, vary the loads on the accessory drive components.
The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the
drive belt may be the only repair for the symptom.
If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the
drive belts are installed, there might be an accessory drive component with a failure. Varying the
load on the different accessory drive components may aid in identifying which component is
causing the rumbling noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that
the symptom is present during diagnosing. Other vehicle components may cause a similar
symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or
vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the
description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When
removing the drive belts the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive
belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt
will not cause the noise. Belt separation is identified by the plys of the belt separating and may be
seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is normal
condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface
for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt,
nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is
driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump
bearings for smooth operation and excessive play. Compare the water pump with a known good
water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put
extra strain on that accessory component causing it to vibrate.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 1158
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 1159
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 1160
Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Diagnostic Aids
If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the
drive belt to fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on
the drive belt.
Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt
for the application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause
the drive belt to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the
drive belt fall off.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify
the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off.
The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for
cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be
caused from improper mounting of the accessory drive component, incorrect installation of the
accessory drive component pulley, or the pulley bent inward or outward from a previous repair.
Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys.
If a misaligned pulley is found refer to that accessory drive component for the proper installation
procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a
dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all
of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to
drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive
belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut ,
spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley
misalignment from the bracket moving under load. Over tightening of the fasteners may cause
misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is
correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by
mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is
too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the
grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any
parts of the engine or body while the engine is operating. There should be sufficient clearance
when the drive belt accessory drive components load varies. The drive belt should not come in
contact with an engine or a body component when snapping the throttle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 1161
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt
Replacement - Accessory
Drive Belt: Service and Repair Drive Belt Replacement - Accessory
Drive Belt Replacement - Accessory
Removal Procedure
1. Open the hood. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet
Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh
Air Duct/Hose/Service and Repair).
3. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 4. Rotate the drive belt
tensioner clockwise in order to relieve tension on the belt. 5. Remove the drive belt (1) from the
pulleys and the drive belt tensioner. 6. Slowly release the tension on the drive belt tensioner. 7.
Remove the breaker bar and socket and from the drive belt tensioner bolt. 8. Clean and inspect the
belt surfaces of all the pulleys.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt
Replacement - Accessory > Page 1164
1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar
with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to
relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release
the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner
bolt. 7. Inspect the drive belt for proper installation and alignment. 8. Install the air cleaner outlet
duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner
Housing/Air Cleaner Fresh
Air Duct/Hose/Service and Repair).
9. Start the vehicle and inspect the drive belt for proper operation.
10. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt
Replacement - Accessory > Page 1165
Drive Belt: Service and Repair Air Conditioning Compressor Belt Replacement
Air Conditioning Compressor Belt Replacement
Removal Procedure
1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt
Replacement - Accessory). 2. Remove the cooling fan. Refer to Fan Replacement (LH8) (See:
Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and
Repair)Fan Replacement (LLV, LLR) (See: Engine, Cooling and Exhaust/Cooling System/Radiator
Cooling Fan/Service and Repair).
3. Cut the belt (1) from air conditioning (A/C) and crankshaft pulleys.
Installation Procedure
1. Position the belt behind the rear face of the balancer (1) and off of the A/C pulley (2). 2. Install
the belt installation tool (3) onto the balancer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt
Replacement - Accessory > Page 1166
3. Slide the belt installation tool (1) upward, installing the belt (2) onto the belt installation tool. 4.
Slide the belt installation tool downward, positioning the belt onto the A/C pulley, applying light
tension to the belt.
5. Position the lower portion of the belt (1) with the ribbed area facing forward.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt
Replacement - Accessory > Page 1167
6. Slowly rotate the crankshaft pulley (1) in a clockwise direction while using finger pressure to pull
the belt (2) forward. Ensure that the ribbed area
of the belt remains facing forward and the belt aligns properly to the A/C pulley.
7. Inspect the drive belt (1) for proper installation and alignment.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt
Replacement - Accessory > Page 1168
8. Rotate the balancer (1) and additional 360 degrees to ensure proper belt installation. 9. Install
the cooling fan. Refer to Fan Replacement (LH8) (See: Engine, Cooling and Exhaust/Cooling
System/Radiator Cooling Fan/Service and
Repair)Fan Replacement (LLV, LLR) (See: Engine, Cooling and Exhaust/Cooling System/Radiator
Cooling Fan/Service and Repair).
10. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt
Replacement - Accessory).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose >
Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Resonator Outlet Duct Replacement
Removal Procedure
1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement
(See: Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct.
3. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose >
Component Information > Service and Repair > Page 1174
4. Loosen the air cleaner outlet duct clamp (1) at the throttle body. 5. Grasp the air cleaner outlet
duct near the ball stud and firmly pull up in order to disengage the duct from the ball stud. 6.
Remove the air cleaner outlet duct (2) from the throttle body and the air cleaner housing.
Installation Procedure
1. Install the air cleaner outlet duct (2) to the throttle body and the air cleaner housing. 2. Ensure
that the air cleaner outlet duct tab rests over the ball stud, press down on the duct tab in order to
engage the duct to the ball stud.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the air cleaner outlet duct clamp (1) at the throttle body.
Tighten the clamp to 3.5 Nm (31 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose >
Component Information > Service and Repair > Page 1175
4. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing.
Tighten the clamp to 3.5 Nm (31 lb in).
5. Install the PCV line (1) to the air cleaner outlet duct. 6. Install the intake manifold cover. Refer to
Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information
> Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Air Cleaner Fresh Air Duct/Hose/Service and
Repair).
2. Release the air cleaner upper housing retainer clips (1).
3. Open the air cleaner upper housing (1). 4. Remove the air filter element (2) from the lower air
cleaner housing. 5. Inspect the air cleaner assembly for debris or damage and repair as necessary.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information
> Service and Repair > Page 1179
1. Install the air filter element (2) to the lower air cleaner housing. 2. Close the air cleaner upper
housing (1).
3. Latch the air cleaner upper housing retainer clips (1). 4. Install the air cleaner outlet duct. Refer
to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service
and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair
Fluid Filter - A/T: Service and Repair
Automatic Transmission Fluid and Filter Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair).
Note: Do not pull on the boot portion of the cable.
2. Complete the following in order to disconnect the range selector cable (3) from the transmission
range selector lever ball stud:
1. Insert a flat-bladed tool between the range selector cable end (5) and the range selector lever
(1). 2. Pry the range selector cable end (5) away from the range selector lever (1).
3. Remove the bolts securing the transmission range selector cable bracket to the transmission.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Page 1183
4. Position the transmission range selector cable bracket aside for clearance while lowering the
pan.
5. Position an appropriate container under the transmission oil pan. 6. Remove the oil pan bolts
from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8.
Lightly tap the oil pan with a rubber mallet in order to loosen the pan, allow the transmission fluid to
drain into the container.
9. Remove the remaining oil pan bolts.
10. Remove the oil pan and the gasket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Page 1184
11. Grasp firmly while pulling down with a twisting motion in order to remove the filter.
12. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use
pliers or another suitable tool to remove the seal.
Discard the seal.
13. Inspect the fluid color. 14. Inspect the filter. The filter may contain the following evidence for
root cause diagnosis:
* Bronze slivers indicating bushing wear
* Clutch material
* Steel particles
15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. All traces
of the old gasket material must be removed.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Page 1185
1. Coat the new filter seal with clean automatic transmission fluid. 2. Install the new filter seal into
the transmission case. Tap the seal into place using a suitable size socket.
3. Install the new filter into the case.
4. Install the oil pan and a new gasket.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Install the oil pan bolts and tighten alternately and evenly to 16 Nm (12 lb ft). 6. Remove the
container used to catch the used transmission fluid from under the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Page 1186
7. Position the transmission range selector cable bracket to the transmission. 8. Install the
transmission range selector cable bracket bolts and tighten to 25 Nm (18 lb ft). 9. Adjust the
automatic transmission range selector cable. Refer to Range Selector Lever Cable Adjustment
(5.3L) (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Shift Linkage/Shift Cable/Adjustments)Range
Selector Lever Cable Adjustment (2.9L and 3.7L) ( See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Shift Linkage/Shift Cable/Adjustments).
10. Lower the vehicle. 11. Fill the transmission to the proper level with DEXRON(R) VI transmission
fluid. Refer to Transmission Fluid Check (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and
General Diagnostics/Transmission Fluid Check) and Fluid Capacity Specifications (See:
Transmission and Drivetrain/Automatic Transmission/Transaxle/Specifications/Capacity
Specifications).
12. Check the COLD fluid level reading for initial fill only. 13. Inspect the oil pan gasket for leaks.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information >
Service and Repair > Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning
(See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Fuses and Circuit Breakers/Fuse/Application and ID).
2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine
cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail
service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten
the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information >
Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1192
Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel
Pressure Relief (With CH 48027))Fuel Pressure
Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)).
2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or
diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's
directions.
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information >
Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1193
1. Relieve the fuel system pressure, if required. Perform the following steps:
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from
the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the
fuel rail service port cap. 6. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information >
Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1194
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH-48027)
Special Tools
CH-48027 - Digital Pressure Gage
Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery
and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Fuses and Circuit Breakers/Fuse/Application and ID).
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information >
Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1195
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT
necessary to proceed with the following steps.
12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4)
from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and
place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the
engine cover, if required. 17. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > Engine - Noise/Damage Oil Filter Application Importance
Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance
INFORMATION
Bulletin No.: 07-06-01-016B
Date: July 27, 2009
Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin
Number 07-06-01-016A (Section 06 - Engine/Propulsion System).
Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is
not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R)
oil filters directly from GMSPO.
Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the
most recent parts information to ensure the correct part number filter is installed when replacing oil
filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been
discovered in some aftermarket parts systems. Always ensure the parts you install are from a
trusted source. Improper oil filter installation may result in catastrophic engine damage.
Refer to the appropriate Service Information (SI) installation instructions when replacing any oil
filter and pay particular attention to procedures for proper cartridge filter element alignment. If the
diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise
or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number
02-00-89-002I (Information for Dealers on How to Submit a Field Product Report).
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > Page 1200
Oil Filter: Service and Repair
Engine Oil and Oil Filter Replacement
Removal Procedure
1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 4. Place a oil drain pan
under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain
completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect
the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the
drain plug hole and reinstall the oil pan drain plug until snug.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > Page 1201
10. Position the drain pan under the oil filter. 11. Remove the oil filter. 12. Ensure that the oil filter
gasket is still on the old filter if not, remove the oil filter gasket from the oil pan.
Installation Procedure
1. Apply clean engine oil to the NEW oil filter seal.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the NEW oil filter.
Tighten the oil filter to 30 Nm (22 lb ft).
3. Tighten the oil pan drain plug.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > Page 1202
Tighten the drain plug to 25 Nm (18 lb ft).
4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new
engine oil. Refer to Approximate Fluid Capacities (See: Service Intervals) and Fluid and Lubricant
Recommendations (
See: Service Intervals).
7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the
oil a few minutes to drain back into the oil pan.
10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil
level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level
indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13.
Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level
indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary,
adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
Coolant Line/Hose: Service and Repair
Engine Coolant Air Bleed Pipe Replacement (With LH8) (5.3L)
Removal Procedure
1. If replacing the rear coolant air bleed covers, remove the intake manifold. Refer to Intake
Manifold Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair). Otherwise proceed to the next step.
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Filters/Air Cleaner Housing/Air Cleaner Fresh
Air Duct/Hose/Service and Repair).
3. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service
and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair).
4. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 5. Remove
the radiator vent inlet hose (2) from the coolant air bleed pipe fitting.
6. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Page 1207
7. Remove the coolant air bleed pipe (307) and seals (308).
8. Remove the coolant air bleed cover bolts (312), if required. 9. Remove the coolant air bleed
covers (313) and seals (308), if required.
10. Remove the seals (308) from the coolant air bleed pipe and/or covers. 11. Discard the seals.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Page 1208
Note: Position the O-ring seal (308) onto the nipple portion of the pipe.
1. Install the seals onto the coolant air bleed pipe and/or covers.
2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the coolant air bleed pipe bolts (309) and tighten to 12 Nm (106 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Page 1209
4. Install the coolant air bleed covers (313) and seals (308), if required. 5. Install the coolant air
bleed cover bolts (312), if required and tighten to 12 Nm (106 lb in).
6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 7. Position the radiator
vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 8. Install the air cleaner outlet duct.
Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air
Cleaner Fresh
Air Duct/Hose/Service and Repair).
9. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service
and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair).
10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to Intake
Manifold Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement
Heater Hose: Service and Repair Heater Inlet Hose Replacement
Heater Inlet Hose Replacement
Tools Required
* J 38185 Hose Clamp Pliers
* J 43181 Heater Line Quick Connect Release Tool
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service
and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair).
2. Using the J 43181 , release the inlet heater hose quick connect (1) from the heater core inlet. 3.
Position the inlet heater hose clamp (4) at the engine block using J 38185 . 4. Remove the heater
inlet hose (3) from the inlet hose fitting (6) at the engine block. 5. Remove the heater inlet hose (3).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement > Page 1214
1. Apply coolant to the end of the heater inlet hose (5).
Important: When installing a new heater inlet hose, place the clamps on the hose before installing
the hose to the inlet hose fitting at the engine block.
2. Install the heater inlet hose (3) to the inlet hose fitting (6) at the engine block. 3. Position the inlet
heater hose clamp (4) at the engine block using J 38185 . 4. Install the heater inlet hose (3) to the
heater core inlet. 5. Press the quick connect (1) onto the heater core inlet until fully seated. 6. Fill
the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement > Page 1215
Heater Hose: Service and Repair Heater Outlet Hose Replacement
Heater Outlet Hose Replacement
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service
and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair).
2. Remove the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (4WD 5.3L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 5.3L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
3. Remove the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and
Charging/Charging System/Alternator/Service and
Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and
Charging/Charging System/Alternator/Service and Repair/Generator Replacement).
4. Using the J 38185 disconnect the outlet hose from the heater core outlet tube. 5. Remove the
heater outlet hose from the heater core.
6. Position the outlet heater hose clamp (6) at the water pump using J 38185 . 7. Remove the
heater outlet hose (7) from the outlet hose fitting. 8. Remove the heater outlet hose.
Installation Procedure
1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3.
Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185 . 4. Install the
heater outlet hose to the heater core. 5. Position the outlet heater hose clamp at the heater core
using J 38185 . 6. Install the transmission. Refer to Transmission Replacement (4WD 2.9L and
3.7L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (4WD 5.3L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 5.3L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement > Page 1216
2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and
Repair/Removal and Replacement).
7. Install the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and
Charging/Charging System/Alternator/Service and
Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and
Charging/Charging System/Alternator/Service and Repair/Generator Replacement).
8. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service
and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement > Page 1217
Heater Hose: Service and Repair Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe
Replacement
Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement > Page 1218
Heater Hose: Service and Repair Heater Inlet Pipe Replacement
Heater Inlet Pipe Replacement
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
2. Using the J 38185 , reposition the heater hose outlet clamp from the heater pipe inlet. 3.
Remove the heater hose outlet from the heater pipe inlet. 4. Remove the exhaust heat shield.
Refer to Exhaust Manifold Heat Shield Replacement (LLV) ()Exhaust Manifold Heat Shield
Replacement (LLR)
().
5. Remove the heater inlet pipe bolt. 6. Remove the heater inlet pipe.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement > Page 1219
1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet
hose fitting threads.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the heater outlet hose fitting. Tighten the heater outlet hose fitting to 45 Nm (33 lb ft). 3.
Install the heater hose outlet to the heater pipe inlet. 4. Using the J 38185 , reposition the heater
hose outlet clamp to the heater pipe inlet. 5. Install the exhaust heat shield. Refer to Exhaust
Manifold Heat Shield Replacement (LLV) ()Exhaust Manifold Heat Shield Replacement (LLR)
().
6. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement > Page 1220
Heater Hose: Service and Repair Heater Outlet Pipe Replacement
Heater Outlet Pipe Replacement
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
2. Using the J 38185 , reposition the heater hose inlet clamp from the heater pipe outlet. 3.
Remove the heater hose inlet from the heater pipe outlet.
4. Loosen the heater pipe outlet. 5. Remove the heater pipe outlet.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement > Page 1221
1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet
hose fitting threads.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the heater outlet hose fitting. Tighten the heater outlet hose fitting to 45 Nm (33 lb ft). 3.
Install the heater hose inlet to the heater pipe outlet. 4. Using the J 38185 , reposition the heater
hose inlet clamp to the heater pipe outlet. 5. Fill the engine cooling system. Refer to Cooling
System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 09-01-38-002 > May > 09 > A/C - Moan/Whine Noise Under Heavy
Load
Hose/Line HVAC: Customer Interest A/C - Moan/Whine Noise Under Heavy Load
TECHNICAL
Bulletin No.: 09-01-38-002
Date: May 14, 2009
Subject: A/C Moan and/or Whine Noise Under Heavy Load Condition (Replace A/C Suction Hose
With Updated Design)
Models:
2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3 , H3T, H3G Export All Equipped
with Engine RPO LH8
Condition
Some customers may comment on a moan and/or a whine type noise when the A/C compressor is
engaged during high system loads. These high load operating conditions include high ambient
temperatures, extended periods of idle operation and towing applications. The noise will stop
immediately when the compressor is disengaged.
Cause
This condition may be caused by the factory installed A/C suction hose lacking sufficient noise
dampening.
Correction
Install a new A/C suction hose assembly. This new hose assembly has an improved noise
dampening design. Refer to Suction Hose Replacement (LH8) in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-01-38-002 > May > 09 > A/C - Moan/Whine Noise
Under Heavy Load
Hose/Line HVAC: All Technical Service Bulletins A/C - Moan/Whine Noise Under Heavy Load
TECHNICAL
Bulletin No.: 09-01-38-002
Date: May 14, 2009
Subject: A/C Moan and/or Whine Noise Under Heavy Load Condition (Replace A/C Suction Hose
With Updated Design)
Models:
2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3 , H3T, H3G Export All Equipped
with Engine RPO LH8
Condition
Some customers may comment on a moan and/or a whine type noise when the A/C compressor is
engaged during high system loads. These high load operating conditions include high ambient
temperatures, extended periods of idle operation and towing applications. The noise will stop
immediately when the compressor is disengaged.
Cause
This condition may be caused by the factory installed A/C suction hose lacking sufficient noise
dampening.
Correction
Install a new A/C suction hose assembly. This new hose assembly has an improved noise
dampening design. Refer to Suction Hose Replacement (LH8) in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Discharge Hose Replacement
Hose/Line HVAC: Service and Repair Discharge Hose Replacement
Discharge Hose Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Discharge Hose Replacement > Page 1237
Hose/Line HVAC: Service and Repair Suction Hose Replacement
Suction Hose Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Discharge Hose Replacement > Page 1238
Hose/Line HVAC: Service and Repair Suction Screen Replacement
Suction Screen Replacement
Tools Required
J 44551 Suction Screen Kit
Removal Procedure
Important: Suction screens are intended to be installed in the suction hose after a major
compressor failure.
1. Remove the A/C suction hose from the A/C compressor. Refer to Suction Hose Replacement
(LH8) (See: Suction Hose Replacement)Suction
Hose Replacement (LLV, LLR) (See: Suction Hose Replacement).
2. Using the J-44551-9 Universal Removal Tool, place the tip of the tool under the inside edge of
the compression band of the suction screen and the
cushioning fulcrum pad against the open end of the hose or manifold fitting.
Important: Do not damage the end of the hose or manifold.
3. Pry upward on the band and move the tool around the diameter of the screen as necessary to
remove the screen.
Installation Procedure
1. Using a caliper that reads to 3 decimal places, measure the ID of the suction hose or manifold
suction fitting. To determine the correct size screen
for the application, refer to Compressor Suction Screen and Tool Selection Specifications (See:
Heating and Air Conditioning/Specifications/Mechanical Specifications/Heating, Ventilation, and Air
Conditioning/Compressor Suction Screen and Tool Selection Specifications).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Discharge Hose Replacement > Page 1239
2. Select and install the correct mandrel (1) on the threaded portion of the installation tool bolt:
* The brass Universal Mandrel is for use on hose fittings with a smooth bore where the screen
installs flush with the end of the fitting.
* The 11.96 mm (0.471 in) Mandrel is only for the 11.96 mm (0.471 in) screen in hose fittings with
an internal hourglass shape where the screen installs at the recessed, reduced diameter point.
3. Install the 11.96 mm (0.471 in) screen in the middle of the reduced diameter point of the fitting.
4. Place the suction hose fitting or suction hose side of the manifold into the installation tool fixture
J-44551-5 (3) so it is supported by the tools legs.
Important: Correct placement of the J-44551-5 is critical.
5. Lubricate the A/C suction screen with the applicable refrigerant oil. 6. Align the screen (2),
basket first; into the suction hose bore then hand tighten the bolt until contact is made between the
hose, screen and tool. 7. Turn the bolt of the installation tool clockwise pressing the screen into the
bore until the mandrel shoulder contacts the end of the hose fitting. 8. Unscrew the bolt and
remove the installation tool from the hose or manifold.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Discharge Hose Replacement > Page 1240
Important: Clean the surface to be used for attaching the label.
9. Install the J-44551-1 Suction Screen Notification Label.
10. Install the A/C hose to the A/C compressor. Refer to Suction Hose Replacement (LH8) (See:
Suction Hose Replacement)Suction Hose
Replacement (LLV, LLR) (See: Suction Hose Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service
Precautions
Power Steering Line/Hose: Service Precautions
Power Steering Hose Disconnected Caution
Caution: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected.
When disconnected, plug or cap all openings of components. Failure to do so could result in
contamination or loss of power steering fluid and damage to the system.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service
Precautions > Page 1244
Power Steering Line/Hose: Service and Repair
Power Steering Gear Inlet and Outlet Hose Replacement (LH8) (5.3L)
Removal Procedure
1. Remove as much power steering fluid from the power steering fluid reservoir as possible. 2.
Remove the engine protection shield. Refer to Engine Protection Shield Replacement (See: Body
and Frame/Frame/Skid Plate/Service and
Repair).
3. Place drain pans under the vehicle as needed.
4. Disconnect the power steering gear inlet and outlet hose (1) from the power steering pump and
power steering fluid reservoir assembly.
5. Remove the power steering gear inlet and outlet hose bracket bolts (2). 6. Remove the power
steering gear inlet and outlet hose retaining plate bolt (1). 7. Disconnect the power steering gear
inlet and outlet hose (3) from the steering gear and remove it from the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service
Precautions > Page 1245
8. Clean the power steering gear inlet and outlet hose ports at the steering gear of any debris. 9.
Transfer any parts as needed.
Installation Procedure
1. Install the power steering gear inlet and outlet hose (3) to the vehicle and connect it to the
steering gear.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the power steering gear inlet and outlet hose retaining plate bolt (1) and tighten to 12 Nm
(106 lb in). 3. Install the power steering gear inlet and outlet hose bracket bolts (2) and tighten to 9
Nm (80 lb in).
4. Connect the power steering gear inlet and outlet hose (1) to the power steering pump and power
steering fluid reservoir assembly. Tighten the
fitting to 25 Nm (18 lb ft).
5. Clean any excess power steering fluid from the vehicle and remove the drain pans. 6. Install the
engine protection shield. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid Plate/Service and Repair). 7. Fill and bleed the power steering system. Refer to
Power Steering System Bleeding (See: Steering and Suspension/Steering/Power
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service
Precautions > Page 1246
Steering/Power Steering Bleeding/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair >
Radiator Inlet Hose Replacement
Radiator Hose: Service and Repair Radiator Inlet Hose Replacement
Radiator Inlet Hose Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair >
Radiator Inlet Hose Replacement > Page 1251
Radiator Hose: Service and Repair Radiator Outlet Hose Replacement
Radiator Outlet Hose Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
HYDRAULIC BRAKE SYSTEM DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 12377967, in
Canada 89021320).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications
Clutch Fluid: Specifications
HYDRAULIC CLUTCH FLUID
GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Cooling System ...................................................................................................................................
.............................................. 13.7 quarts (13.0 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 1263
Coolant: Fluid Type Specifications
ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant.
This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km),
whichever occurs first, if you add only DEX-COOL extended life coolant.
A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: Give freezing protection
down to -34°F (-37°C). Give boiling protection up to 265°F (129°C). Protect against rust and
corrosion. Help keep the proper engine temperature. Let the warning lights and gages work as they
should.
NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or
radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles
(50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your
warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle.
WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant
which won't damage aluminum parts. If you use this coolant mixture, you don't need to add
anything else.
CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some
other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant
warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your
engine could get too hot but you would not get the overheat warning. Your engine could catch fire
and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL
coolant.
NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly
damaged. The repair cost would not be covered by your warranty. Too much water in the mixture
can freeze and crack the engine, radiator, heater core and other parts.
If you have to add coolant more than four times a year, check your cooling system.
NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle
could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins
> A/T - Water Or Coolant Contamination Information
Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information
INFORMATION
Bulletin No.: 08-07-30-035B
Date: November 01, 2010
Subject: Information on Water or Ethylene Glycol in Transmission Fluid
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission
Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin
Number 08-07-30-035A (Section 07 - Transmission/Transaxle).
Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission
components and will have a negative effect on reliability and durability of these parts. Water or
ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder
during engagement or gear changes, especially during torque converter clutch engagement.
Indications of water in the ATF may include:
- ATF blowing out of the transmission vent tube.
- ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a
strawberry milkshake.
- Visible water in the oil pan.
- A milky white substance inside the pan area.
- Spacer plate gaskets that appear to be glued to the valve body face or case.
- Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not
compressed.
- Rust on internal transmission iron/steel components.
If water in the ATF has been found and the source of the water entry has not been identified, or if a
leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in
the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of
ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be
obtained and the ATF tested to make an accurate decision on the need for radiator replacement.
This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking
and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These
test kits can be obtained from:
Nelco Company
Test kits can be ordered by phone or through the website listed above. Orders are shipped
standard delivery time but can be shipped on a next day delivery basis for an extra charge. One
test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost
of the complete test kit plus shipping charges should be divided by 10 and submitted on the
warranty claim as a net item.
The transmission should be repaired or replaced based on the normal cost comparison procedure.
Important If water or coolant is found in the transmission, the following components MUST be
replaced.
- Replace all of the rubber-type seals.
- Replace all of the composition-faced clutch plates and/or bands.
- Replace all of the nylon parts.
- Replace the torque converter.
- Thoroughly clean and rebuild the transmission, using new gaskets and oil filter.
Important The following steps must be completed when repairing or replacing.
Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number
02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096
TransFlow.
- Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins
> A/T - Water Or Coolant Contamination Information > Page 1268
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
AUTOMATIC TRANSMISSION FLUID Pan Removal .........................................................................
..................................................................................................................... 4.7 liters (5.0 qts)
Overhaul ..............................................................................................................................................
................................................... 10.6 liters (11.0 qts) With 245 mm Torque Converter Dry Fill .........
..............................................................................................................................................................
................................ 8.3 liters (8.8 qts) With 258 mm Torque Converter Dry Fill ................................
..............................................................................................................................................................
......... 8.8 liters (9.3 qts)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 1271
Fluid - A/T: Fluid Type Specifications
AUTOMATIC TRANSAXLE FLUID
DEXRON-VI Automatic Transmission Fluid.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1272
Fluid - A/T: Testing and Inspection
Transmission Fluid Check
This procedure checks the transmission fluid level, as well as the condition of the fluid itself.
Caution: Always use the proper automatic transmission fluid listed. Using incorrect automatic
transmission fluid may damage the vehicle.
Before checking the fluid level, perform the following:
1. Start the engine and park the vehicle on a level surface. Keep the engine running. 2. Apply the
parking brake and place the shift lever in PARK (P). 3. Depress the brake pedal and move the shift
lever through each gear range, pausing for about 3 seconds in each range. Then, move the shift
lever
back to PARK (P).
4. Allow the engine to idle 500-800 RPM for at least 1 minute. Slowly release the brake pedal. 5.
Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver
Information Center (DIC) or a scan tool. 6. Using the TFT reading, determine and perform the
appropriate check procedure. If the TFT reading is not within the required temperature ranges,
allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached.
Cold Check Procedure
Note: *
Use the cold check procedure only as a reference to determine if the transmission has enough fluid
to be operated safely until a hot check procedure can be made. The hot check procedure is the
most accurate method to check the fluid level. Perform the hot check procedure at the first
opportunity.
* Use this cold check procedure to check fluid level when the TFT is between 27-32°C (80-90°F).
1. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on
the passenger's side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe
the dipstick end with a clean rag or paper towel. 3. Install the dipstick by pushing it back in the
dipstick tube all the way, wait three seconds and then pull it back out again.
Note: Always check the fluid level at least twice. Consistent readings are important to maintaining
proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to
ensure it is clean and unclogged.
4. Keep the dipstick pointing down and check both sides of the dipstick, and read the lower level.
Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick.
Refer to Fluid Condition Inspection in this procedure. 6. If the fluid level is below the COLD check
line, add only enough fluid as necessary to bring the level into the COLD line. It does not take
much
fluid, generally less than one pint (0.5L). Do not overfill.
7. If the fluid level is in the acceptable range, push the dipstick back in all the way, then flip the
handle down to lock the dipstick in place. 8. Perform a hot check at the first opportunity after the
transmission reaches a normal operating temperature between 82-93°C (180-200°F).
Hot Check Procedure
Note: Use this procedure to check the transmission fluid level when the TFT is between 82-93°C
(180-200°F). The hot check procedure is the most accurate method to check the fluid level. The hot
check should be performed at the first opportunity in order to verify the cold check. The fluid level
rises as fluid temperature increases, so it is important to ensure the transmission temperature is
within range.
1. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on
the passenger side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe the
dipstick end with a clean rag or paper towel. 3. Install the dipstick by pushing it back in the dipstick
tube all the way, wait three seconds and then pull it back out.
Note: Always check the fluid level at least twice. Consistent readings are important to maintaining
proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to
ensure it is clean and unclogged.
4. Keep the dipstick tip pointing down and check both sides of the dipstick. Read the lower level.
Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick.
Refer to Fluid Condition Inspection. 6. A safe operating fluid level is within the HOT crosshatch
band on the dipstick. If the fluid level is not within the HOT band, and the transmission
temperature is between 82-93°C (180-200°F), add or drain fluid as necessary to bring the level into
the HOT band. If the fluid level is low, add only enough fluid to bring the level into the HOT band.
Note: To assist in reaching the correct temperature range of 82-93°C (180-200°F), drive the vehicle
in second gear at no more than 65 mph until the desired temperature is reached.
7. If the fluid level is low, add only enough fluid to bring the level into the HOT band. It does not
take much fluid, generally less than one pint
(0.5L). Do not overfill. Also, if the fluid level is low, inspect the transmission for leaks. Refer to Fluid
Leak Diagnosis (See: Transmission and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1273
Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and
General Diagnostics/Fluid Leak Diagnosis).
8. If the fluid level is in the acceptable range, push the dipstick back into the dipstick tube all the
way, and then flip the handle down to lock the
dipstick in place.
9. If applicable and if the vehicle is equipped, reset the transmission oil life monitor only if the fluid
was changed.
Fluid Condition Inspection
Inspect the fluid color. The fluid should be red or dark brown.
* If the fluid color is very dark or black and has a burnt odor, inspect the fluid and inside of the
bottom pan for excessive metal particles or other debris. A small amount of "friction" material in the
bottom pan is a "normal" condition. If large pieces and/or metal particles are noted in the fluid or
bottom pan, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs
of transmission internal damage noted, replace the fluid filter assembly, repair the oil cooler, and
flush the cooler lines.
* Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or
water contamination. Refer to Engine Coolant/Water in Transmission (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic
Procedures/Engine Coolant/Water in Transmission).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1274
Fluid - A/T: Service and Repair
Automatic Transmission Fluid and Filter Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair).
Note: Do not pull on the boot portion of the cable.
2. Complete the following in order to disconnect the range selector cable (3) from the transmission
range selector lever ball stud:
1. Insert a flat-bladed tool between the range selector cable end (5) and the range selector lever
(1). 2. Pry the range selector cable end (5) away from the range selector lever (1).
3. Remove the bolts securing the transmission range selector cable bracket to the transmission.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1275
4. Position the transmission range selector cable bracket aside for clearance while lowering the
pan.
5. Position an appropriate container under the transmission oil pan. 6. Remove the oil pan bolts
from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8.
Lightly tap the oil pan with a rubber mallet in order to loosen the pan, allow the transmission fluid to
drain into the container.
9. Remove the remaining oil pan bolts.
10. Remove the oil pan and the gasket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1276
11. Grasp firmly while pulling down with a twisting motion in order to remove the filter.
12. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use
pliers or another suitable tool to remove the seal.
Discard the seal.
13. Inspect the fluid color. 14. Inspect the filter. The filter may contain the following evidence for
root cause diagnosis:
* Bronze slivers indicating bushing wear
* Clutch material
* Steel particles
15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. All traces
of the old gasket material must be removed.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1277
1. Coat the new filter seal with clean automatic transmission fluid. 2. Install the new filter seal into
the transmission case. Tap the seal into place using a suitable size socket.
3. Install the new filter into the case.
4. Install the oil pan and a new gasket.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Install the oil pan bolts and tighten alternately and evenly to 16 Nm (12 lb ft). 6. Remove the
container used to catch the used transmission fluid from under the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1278
7. Position the transmission range selector cable bracket to the transmission. 8. Install the
transmission range selector cable bracket bolts and tighten to 25 Nm (18 lb ft). 9. Adjust the
automatic transmission range selector cable. Refer to Range Selector Lever Cable Adjustment
(5.3L) (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Shift Linkage/Shift Cable/Adjustments)Range
Selector Lever Cable Adjustment (2.9L and 3.7L) ( See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Shift Linkage/Shift Cable/Adjustments).
10. Lower the vehicle. 11. Fill the transmission to the proper level with DEXRON(R) VI transmission
fluid. Refer to Transmission Fluid Check (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and
General Diagnostics/Transmission Fluid Check) and Fluid Capacity Specifications (See:
Transmission and Drivetrain/Automatic Transmission/Transaxle/Specifications/Capacity
Specifications).
12. Check the COLD fluid level reading for initial fill only. 13. Inspect the oil pan gasket for leaks.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity
Specifications
Fluid - M/T: Capacity Specifications
Manual Transmission Fluid ..................................................................................................................
................................................. 2.2 liters (2.3 quarts)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity
Specifications > Page 1283
Fluid - M/T: Fluid Type Specifications
MANUAL TRANSMISSION FLUID SAE 75W-90, API AI-A or GL-3 GM Part No. U.S. 89021806, in
Canada 89021807.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1284
Fluid - M/T: Service and Repair
Transmission Fluid Replacement
Draining Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair).
2. Clean away all dirt and debris from the transmission fluid drain plug area. 3. Position an
appropriate container under the transmission. 4. Remove the transmission fluid drain plug and
washer.
Discard the washer. Allow the transmission fluid to drain into the container.
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
5. Install the transmission fluid drain plug and NEW washer.
Tighten the drain plug to 37 Nm (27 lb ft).
6. Remove the container used to catch the used transmission fluid from under the vehicle.
Filling Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1285
1. Clean away all dirt and debris from the transmission fluid fill plug area. 2. Remove the
transmission fluid fill plug and washer.
Discard the washer.
3. Fill the transmission to just below the bottom of the fill plug hole with the recommended fluid.
Refer to Lubrication Specifications (See:
Transmission and Drivetrain/Manual Transmission/Transaxle/Specifications/Fluid Type
Specifications).
4. Install the transmission fluid fill plug and NEW washer.
Tighten the fill plug to 37 Nm (27 lb ft).
5. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications >
Capacity Specifications
Fluid - Differential: Capacity Specifications
DIFFERENTIAL FLUID Front Axle ......................................................................................................
......................................................................................... 1.5 liters (3.2 pints) Rear Axle 8.0 inch ......
..............................................................................................................................................................
............................... 1.7 liters (3.6 pints) 8.6 inch ................................................................................
................................................................................................................. 2.03 liters (4.3 pints)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications >
Capacity Specifications > Page 1290
Fluid - Differential: Fluid Type Specifications
FRONT AND REAR AXLE SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in
Canada 89021678) meeting GM Specification 9986115.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair >
Procedures
Fluid - Differential: Procedures
Front Drive Axle
Front Axle Lubricant Level Inspection
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and
Repair). 2. Ensure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4.
Remove the engine protection shield (EPS), if equipped. Refer to Engine Protection Shield
Replacement (See: Body and Frame/Frame/Skid
Plate/Service and Repair).
5. Clean the area around the front axle fill plug. 6. Remove the front axle fill plug and the washer. 7.
Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L".
Note: Ensure that the pipe cleaner is resting on the bottom threads of the fill hole.
8. Insert the pipe cleaner into the fill plug opening with the stem "L" is facing down. 9. Remove the
pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level.
The oil level should be between 0-8 mm (0-0.4 in) below the fill plug opening.
10. If the level is low, add fluid until the level is within the proper fluid level specification. Use the
proper fluid. Refer to Fluid and Lubricant
Recommendations (See: Service Intervals).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
11. Install the fill plug and the washer and tighten the plug to 32 Nm (24 lb ft). 12. Install the EPS, if
equipped. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid
Plate/Service and Repair). 13. Lower the vehicle.
Rear Axle Lubricant Level Inspection (8.0 Inch Axle)
Rear Axle Lubricant Level Inspection (8.0 Inch Axle)
Note: All axle assemblies are filled by volume of fluid during production. They are not filled to reach
a certain level. When checking the fluid level on any axle, variations in the readings can be caused
by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle
has just been driven before checking the fluid level, it may appear lower than normal because the
fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a
reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level
than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly
must be supported to get a true reading.
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and
Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4.
Clean the area around the rear axle fill plug.
5. Remove the rear axle fill plug. 6. Inspect the lubricant level.
The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair >
Procedures > Page 1293
7. If the fluid level is low, add lubricant until the level is within specifications. Use the proper fluid.
Refer to Adhesives, Fluids, Lubricants, and
Sealers (See: Transmission and Drivetrain/Differential Assembly/Specifications/Fluid Type
Specifications).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle.
Rear Axle Lubricant Level Inspection (8.6 Inch Axle)
Rear Axle Lubricant Level Inspection (8.6 Inch Axle)
Note: All axle assemblies are filled by volume of fluid during production. They are not filled to reach
a certain level. When checking the fluid level on any axle, variations in the readings can be caused
by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle
has just been driven before checking the fluid level, it may appear lower than normal because the
fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a
reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level
than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly
must be supported to get a true reading.
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and
Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4.
Clean the area around the rear axle fill plug.
5. Remove the rear axle fill plug. 6. Inspect the lubricant level.
The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening.
7. If the fluid level is low, add lubricant until the level is within specifications. Use the proper fluid.
Refer to Adhesives, Fluids, Lubricants, and
Sealers (See: Transmission and Drivetrain/Differential Assembly/Specifications/Fluid Type
Specifications).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair >
Procedures > Page 1294
Fluid - Differential: Removal and Replacement
Front Drive Axle
Front Axle Lubricant Replacement
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and
Repair). 2. Ensure that the vehicle is level. 3. Remove the engine protection shield (EPS), if
equipped. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid
Plate/Service and Repair).
4. Remove the drain plug. 5. Drain axle fluid into a suitable container.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the drain plug and tighten to 32 Nm (24 lb ft). 7. Remove the fill plug. 8. Fill the drive axle
with the proper fluid. Refer to Fluid and Lubricant Recommendations (See: Service Intervals). 9.
Inspect the fluid level. Refer to Front Axle Lubricant Level Inspection (See: Procedures/Front Drive
Axle).
10. Install the fill plug and tighten to 32 Nm (24 lb ft). 11. Install the EPS, if equipped. Refer to
Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and
Repair). 12. Lower the vehicle.
Rear Axle Lubricant Replacement (8.0 Inch Axle)
Rear Axle Lubricant Replacement (8.0 Inch Axle)
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and
Repair). 2. Clean the area around the rear axle fill plug. 3. Remove the rear axle fill plug. 4.
Remove the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (See:
Transmission and Drivetrain/Differential
Assembly/Differential Cover/Service and Repair).
5. Drain the lubricant into a suitable container.
Installation Procedure
1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (See:
Transmission and Drivetrain/Differential
Assembly/Differential Cover/Service and Repair).
2. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities
(See: Service Intervals) and Adhesives, Fluids,
Lubricants, and Sealers (See: Transmission and Drivetrain/Differential
Assembly/Specifications/Fluid Type Specifications).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 4. Lower the vehicle.
Rear Axle Lubricant Replacement (8.6 Inch Axle)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair >
Procedures > Page 1295
Rear Axle Lubricant Replacement (8.6 Inch Axle)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Clean the area around the rear axle fill plug.
3. Remove the rear axle fill plug. 4. Remove the rear axle cover. Refer to Rear Axle Housing Cover
and Gasket Replacement (See: Transmission and Drivetrain/Differential
Assembly/Differential Cover/Service and Repair).
5. Drain the lubricant into a suitable container.
Installation Procedure
1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (See:
Transmission and Drivetrain/Differential
Assembly/Differential Cover/Service and Repair).
2. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities
(See: Service Intervals) and Adhesives, Fluids,
Lubricants, and Sealers (See: Transmission and Drivetrain/Differential
Assembly/Specifications/Fluid Type Specifications).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair >
Procedures > Page 1296
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution) /.
3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> Engine - GM dexos 1 and dexos 2(R) Oil Specifications
Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications
INFORMATION
Bulletin No.: 11-00-90-001
Date: March 14, 2011
Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for
Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or
Complete Oil Change
Models:
2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with
Duramax(TM) Diesel Engines
GM dexos 1(TM) Information Center Website
Refer to the following General Motors website for dexos 1(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 1(TM) Engine Oil Trademark and Icons
The dexos(TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM)
specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
1(TM) engine oil.
GM dexos 1(TM) Engine Oil Specification
Important General Motors dexos 1(TM) engine oil specification replaces the previous General
Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The
oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains
acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be
used in those older vehicles.
In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine
oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil
specification are as follows:
- To meet environmental goals such as increasing fuel efficiency and reducing engine emissions.
- To promote long engine life.
- To minimize the number of engine oil changes in order to help meet the goal of lessening the
industry's overall dependence on crude oil.
dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the
following benefits:
- Further improve fuel economy, to meet future corporate average fuel economy (CAFE)
requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits
throughout the life of the oil.
- More robust formulations for added engine protection and aeration performance.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1301
- Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life
has been depleted.
- Reduce the duplication of requirements for a large number of internal GM engine oil
specifications.
International Lubricants Standardization and Approval Committee (ILSAC)
GF-5 Standard
In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval
Committee (ILSAC) standard called GF-5, was introduced in October 2010.
- There will be a corresponding API category, called: SN Resource Conserving. The current GF-4
standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos
1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a
statistically significant increase in fuel economy versus the Sequence VIB test that was used for
GF-4.
- It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard.
However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification.
- Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API
will begin licensing marketers during October 2010, to produce and distribute GF-5 certified
products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils.
Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy
Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than
doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed
CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet
these future requirements, all aspects of vehicle operation are being looked at more critically than
ever before.
New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel
economy include direct injection, cam phasing, turbocharging and active fuel management (AFM).
The demands of these new technologies on engine oil also are taken into consideration when
determining new oil specifications. AFM for example can help to achieve improved fuel economy.
However alternately deactivating and activating the cylinders by not allowing the intake and
exhaust valves to open contributes to additional stress on the engine oil.
Another industry trend for meeting tough fuel economy mandates has been a shift toward lower
viscosity oils.
dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs:
SAE 0W-20, 5W-20, 0W-30 and 5W-30.
Using the right viscosity grade oil is critical for proper engine performance. Always refer to the
Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being
serviced.
GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals
To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the
GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000
mile (4,830 km) recommendation.
The dexos (TM) specification, with its requirements for improved oil robustness, compliments the
GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle.
If all GM customers with GM Oil Life System equipped vehicles would use the system as intended,
GM estimates that more than 100 million gallons of oil could be saved annually.
GM dexos 2(TM) Information Center Website
Refer to the following General Motors website for dexos 2(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 2(TM) Engine Oil Trademark and Icons
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1302
The dexos (TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos (TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos
(TM)specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
2(TM) engine oil.
GM dexos 2(TM) Engine Oil Specification
- dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010
vehicles, regardless of where the vehicle was manufactured.
- dexos 2(TM) is the recommended service fill oil for European gasoline engines.
Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting
specification CJ-4.
- dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and
replaces GM-LL-B-025 and GM-LL-A-025.
- dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on
certain chemical components to prolong catalyst life and protect expensive emission reduction
systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum
performance longer.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil with Filter ............................................................................................................................
............................................... 6.0 quarts (5.7 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 1305
Engine Oil: Fluid Type Specifications
ENGINE OIL
Look for three things:
1. Use only an oil that meets GM Standard GM6094M.
2. Temperatures above -20°F (-29°C), SAE 5W-30 is best for the vehicle. These numbers on an oil
container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 10W-40,
SAE 20W-50 or any other viscosity grade oil not recommended.
3. American Petroleum Institute (API) starburst symbol
Oils meeting these requirements should have the starburst symbol on the container. This symbol
indicates that the oil has been certified by the American Petroleum Institute (API).
Notice: Use only engine oil identified as meeting GM Standard GM6094M and showing the
American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the
recommended oil can result in engine damage not covered by the vehicle warranty.
COLD TEMPERATURE OPERATION If in an area of extreme cold, where the temperature falls
below -20°F (-29°C), use either an SAE 5W-30 synthetic oil or an SAE 0W-30 engine oil. Both
provide easier cold starting for the engine at extremely low temperatures. Always use an oil that
meets the required specification, GM6094M.
ENGINE OIL ADDITIVES / ENGINE OIL FLUSHES Do not add anything to the oil. The
recommended oils with the starburst symbol that meet GM Standard GM6094M are all that is
needed for good performance and engine protection.
Engine oil system flushes are not recommended and could cause engine damage not covered by
the vehicle warranty.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1306
Engine Oil: Service and Repair
Engine Oil and Oil Filter Replacement
Removal Procedure
1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 4. Place a oil drain pan
under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain
completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect
the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the
drain plug hole and reinstall the oil pan drain plug until snug.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1307
10. Position the drain pan under the oil filter. 11. Remove the oil filter. 12. Ensure that the oil filter
gasket is still on the old filter if not, remove the oil filter gasket from the oil pan.
Installation Procedure
1. Apply clean engine oil to the NEW oil filter seal.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the NEW oil filter.
Tighten the oil filter to 30 Nm (22 lb ft).
3. Tighten the oil pan drain plug.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1308
Tighten the drain plug to 25 Nm (18 lb ft).
4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new
engine oil. Refer to Approximate Fluid Capacities (See: Service Intervals) and Fluid and Lubricant
Recommendations (
See: Service Intervals).
7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the
oil a few minutes to drain back into the oil pan.
10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil
level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level
indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13.
Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level
indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary,
adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications
Power Steering Fluid: Specifications
POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N
89021186) or equivalent.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Refrigerant System Capacities
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 1316
Refrigerant: Fluid Type Specifications
Refrigerant System Capacities
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
Refrigerant System Capacities
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 1321
Refrigerant Oil: Fluid Type Specifications
Refrigerant System Capacities
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins >
Customer Interest for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel
Brake Bleeding: Customer Interest Brakes - Brake Pedal Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins >
Customer Interest for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel >
Page 1330
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins >
Customer Interest for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel >
Page 1331
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal
Travel
Brake Bleeding: All Technical Service Bulletins Brakes - Brake Pedal Spongy/Increased Pedal
Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal
Travel > Page 1337
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal
Travel > Page 1338
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > Page 1339
Brake Bleeding: By Symptom
Technical Service Bulletin # 09-05-25-003 Date: 090921
Brakes - Brake Pedal Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > Page 1340
List of Affected Units
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > Page 1341
Disclaimer
Technical Service Bulletin # 09-05-25-003 Date: 090921
Brakes - Brake Pedal Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > Page 1342
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > Page 1343
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 09-05-25-003 Date: 090921
Brakes - Brake Pedal Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > Page 1344
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > Page 1345
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure
Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure
Antilock Brake System Automated Bleed Procedure
Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes
and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint
and Electrical Components Caution).
Note: The base hydraulic brake system must be bled before performing this automated bleeding
procedure. If you have not yet performed the base hydraulic brake system bleeding procedure,
refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding
(Pressure) ( See: ) before proceeding.
1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the
brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the
automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated
bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF.
7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the
maximum-fill level with Delco Supreme 11(R) GM P/N 12377967 (Canadian P/N 992667) or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See:
)Hydraulic Brake System Bleeding (Pressure) (
See: ).
10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in
order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal.
Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated
bleeding procedure. If the brake pedal still feels spongy after repeating the automated
bleeding procedure inspect the brake system for external leaks. Refer to Brake System External
Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and
Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection).
13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp
remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the
vehicle to be driven until it is diagnosed and repaired. Refer to
Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes).
15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake
pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a
firm brake pedal is obtained.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 1348
Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding
Manual
Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See:
Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant
Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes
and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint
and Electrical Components Caution).
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With
the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, you
must perform the following steps:
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add
GM approved brake fluid from a clean,
sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (See: Service
Intervals). If removal of the reservoir cap and diaphragm is necessary, clean the outside of the
reservoir on and around the cap prior to removal.
2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
brake pipe from the front port of the brake
master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4.
Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant
slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the
same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe,
then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps
3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe
installed securely to the master cylinder, after all air has been purged from the front port of the
master cylinder,
loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8.
10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake
pipe-to-master cylinder fittings are properly
tightened.
4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake
fluid container. Refer to Master Cylinder
Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake Master
Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Ensure that the brake
master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as
needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir
cap prior to removing the cap and diaphragm.
5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6.
Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the
transparent hose into a transparent container partially filled with GM approved brake fluid from a
clean, sealed
brake fluid container. Refer to Fluid and Lubricant Recommendations (See: Service Intervals).
8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the
pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit.
10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15
seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12.
With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been
purged from the right rear hydraulic circuit install
a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With
the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left
rear hydraulic circuit, install a proper
box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With
the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the right front hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly
tightened.
19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid
from a clean, sealed brake fluid container. Refer
to Master Cylinder Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake
Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling).
20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the
brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy
after repeating the bleeding procedure,
perform the following steps:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 1349
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Brakes and Traction Control/Hydraulic
System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External
Leak Inspection).
2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in
the system.
22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven
until it is diagnosed and repaired.
23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes
(See: Brakes and Traction Control/Hydraulic
System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic
Brakes).
Pressure
Hydraulic Brake System Bleeding (Pressure)
Special Tools
* J-29532 - Diaphragm Pressure Bleeder, or equivalent
* J-35589-A - Brake Pressure Bleeder Adapter
Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service
Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes
and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint
and Electrical Components Caution).
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With
the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, you
must perform the following steps:
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add
GM approved brake fluid from a clean,
sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brakes and Traction
Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder
Reservoir Filling). If removal of the reservoir cap and diaphragm is necessary, clean the outside of
the reservoir on and around the cap prior to removal.
2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
brake pipe from the front port of the brake
master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4.
Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant
slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the
same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe,
then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps
3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe
installed securely to the master cylinder, after all air has been purged from the front port of the
master cylinder,
loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8.
10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake
pipe-to-master cylinder fittings are properly
tightened.
4. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid
from a clean, sealed brake fluid container.
Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and
diaphragm.
5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6.
Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or
equivalent. Add GM approved brake fluid from a
clean, sealed brake fluid container as necessary to bring the level to approximately the half-full
point.
7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, to the
J-35589-A - Brake Pressure Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Pressure
Bleeder, or equivalent , or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 Diaphragm Pressure Bleeder, or equivalent , or equivalent, fluid tank valve to allow pressurized
brake fluid to enter the brake
system.
10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to
ensure that there are no existing external brake fluid
leaks. Any brake fluid leaks identified require repair prior to completing this procedure.
11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the
transparent hose into a transparent container partially filled with GM approved brake fluid from a
clean, sealed
brake fluid container.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 1350
14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air
bubbles stop flowing from the bleeder, then
tighten the bleeder valve.
15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been
purged from the right rear hydraulic circuit,
install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With
the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the left rear hydraulic circuit, install a
proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With
the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the right front hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly
tightened.
22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, fluid tank valve,
then disconnect the J-29532 - Diaphragm
Pressure Bleeder, or equivalent , or equivalent, from the J-35589-A - Brake Pressure Bleeder
Adapter.
23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder
reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved
brake fluid from a clean, sealed brake fluid container. Refer
to Master Cylinder Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake
Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling)
25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the
brake pedal feels spongy perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Brakes and Traction Control/Hydraulic
System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External
Leak Inspection).
2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove
any air that may have been trapped in the brake
pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed Procedure
(See: ).
27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven
until it is diagnosed and repaired.
28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes
(See: Brakes and Traction Control/Hydraulic
System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic
Brakes).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 1351
Brake Bleeding: Service and Repair Hydraulic Brake System Flushing
Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and
Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
* Fluid separation, indicating two types of fluid are present; a substance other than the
recommended brake fluid has been introduced into the brake hydraulic system
- Swirled appearance - oil-based substance
- Layered appearance - silicone-based substance
* Fluid discoloration, indicating the presence of moisture or particles that have been introduced into
the brake hydraulic system
- Cloudy appearance - moisture
- Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating brake fluid
contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated
by fluid separation and/or a swollen master
cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform
the following:
1. Remove ALL of the following components listed from the vehicle. Each component contains
internal rubber seals/linings which have been
contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the
procedures indicated:
* Master Cylinder Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Master
Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)
* Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Rear Brake Hose Replacement)
* Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Brake Caliper Replacement)
* Wheel Cylinder Replacement (See: Brakes and Traction Control/Drum Brake System/Wheel
Cylinder/Service and Repair)
* Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes
/ Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair)
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake
pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed
and install them to the vehicle. Each component contains internal rubber
seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic
system. Refer to the procedures indicated:
* Master Cylinder Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Master
Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) ; also
perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or
equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks
and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (See:
Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal
and Replacement/Master Cylinder Reservoir Replacement). Replace the brake master cylinder
reservoir cap diaphragm.
* Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Rear Brake Hose Replacement)
* Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Brake Caliper Replacement)
* Wheel Cylinder Replacement (See: Brakes and Traction Control/Drum Brake System/Wheel
Cylinder/Service and Repair) , if equipped
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 1352
* Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes
/ Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair)
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but
WAS contaminated with water or dirt, rust,
corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The
diaphragm may have allowed the moisture or particles to enter the hydraulic system.
5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM
P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder
reservoir filled to the maximum-fill level with the correct
brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic
Brake System Bleeding (Pressure) (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and
Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations).
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Warning
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR
deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power
to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG
warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See:
Diagrams/Electrical Diagrams/Air Bag Systems) or
Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID).
4. Wait 1 minute before working on the system.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and
Repair > Page 1356
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to
SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical
Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to
Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
4. Wait 1 minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer
to Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > Customer Interest: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start
Fuse: Customer Interest Electrical - Dead Battery/No Crank/No Start
TECHNICAL
Bulletin No.: 08-06-03-010
Date: September 30, 2008
Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC)
Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System
Message (Install 125 Amp Mega Fuse)
Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3
Condition
Some customers may comment on the following conditions:
^ The battery runs down.
^ The engine will not crank.
^ The engine will not start.
^ The Instrument Panel Cluster charge indicator turns on.
^ The Driver Information Center displays a Service Charge System message.
Cause
This condition may be caused by an open Mega Fuse in the underhood electrical center.
Correction
Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new
Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently
has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > Customer Interest: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start > Page
1366
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start
Fuse: All Technical Service Bulletins Electrical - Dead Battery/No Crank/No Start
TECHNICAL
Bulletin No.: 08-06-03-010
Date: September 30, 2008
Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC)
Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System
Message (Install 125 Amp Mega Fuse)
Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3
Condition
Some customers may comment on the following conditions:
^ The battery runs down.
^ The engine will not crank.
^ The engine will not start.
^ The Instrument Panel Cluster charge indicator turns on.
^ The Driver Information Center displays a Service Charge System message.
Cause
This condition may be caused by an open Mega Fuse in the underhood electrical center.
Correction
Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new
Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently
has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start
> Page 1372
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Fuse: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From
(HVAC) System
Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System
TECHNICAL
Bulletin No.: 99-01-39-004C
Date: June 12, 2009
Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating)
Models:
1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All
Equipped with Air Conditioning
Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard
Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC).
Condition
Some customers may comment about musty odors emitted from the Heating, Ventilation and Air
Conditioning (HVAC) system at vehicle start-up in hot, humid conditions.
Cause
This condition may be caused by condensate build-up on the evaporator core, which does not
evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on
the evaporator core. When the blower motor fan is turned on, the microbial growth may release an
unpleasant musty odor into the passenger compartment.
There are several other possible sources of a musty odor in a vehicle. A common source is a water
leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow
the procedures in SI for identifying and correcting water leaks and air inlet inspection.
The procedure contained in this bulletin is only applicable if the odor source has been determined
to be microbial growth on the evaporator core inside the HVAC module.
Correction
Many vehicles currently incorporate an afterblow function within the HVAC control module
software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the
evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to
confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded
afterblow feature, as defined in the SI document for that specific vehicle model, model year and
specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in
areas prone to high humidity conditions may benefit from having the afterblow enabled calibration
installed prior to any customer comment.
Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may
be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876).
Important When installing the Electronic Evaporator Dryer Module, you MUST use the included
electrical splice connectors to ensure a proper splice. Complete detailed installation instructions
and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer
Module may be installed underhood if it is protected from extreme heat and water splash areas.
To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to
eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the
following procedure:
Vehicle and Applicator Tool Preparation
1. The evaporator core must be dry. This may be accomplished by disabling the compressor and
running the blower fan on the recirc heat setting for
an extended period of time.
Note Compressor engagement will cause the evaporator core to remain wet and will prevent full
adherence of the Coiling Coil Coating to the evaporator core surfaces.
2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Fuse: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From
(HVAC) System > Page 1378
3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air
filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product
may clog the filter. If the
cabin air filter appears to have little or no remaining life, suggest a replacement to your customer.
5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE
COOLING COIL COATING INTO THE
BLOWER MOTOR COOLING TUBE.
6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line
operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well.
Screw the bottle onto the cap on the applicator tool's pick-up tube.
Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil
slightly in the bottom of a 120 ml (4 oz) bottle.
8. Use one of the following three methods to apply the Cooling Coil Coating.
Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil
Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)).
Application Through Blower Motor Control Module Opening
- Remove the blower motor control module (blower motor resistor). Refer to the applicable
procedure in SI.
- Clean any debris or foreign material from inside the HVAC module and on the evaporator core
surface.
- Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower
motor control module (blower motor resistor) opening.
- Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and
surrounding gasket surfaces.
- When the application is complete, install the blower motor blower motor control module (blower
motor control module).
Application Through Blower Motor Opening
- Remove the blower motor. Refer to the applicable blower motor removal procedure in SI.
- Clean any debris or foreign material from inside the HVAC module and on the evaporator core
surface.
- Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening.
- Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and
surrounding gasket surfaces.
- When the application is complete, install the blower motor.
Application Through a Hole in the HVAC Module
- If neither of the two previous application methods are available, it may be necessary to drill a hole
in the HVAC module.
- Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10
mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and
the blower motor fan.
- With the air distribution vents closed and the blower motor fan speed on HIGH, insert the
applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the
evaporator core.
- Use a GM approved RTV sealant to plug the hole in the HVAC module.
9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately
10 minutes, with the compressor disabled,
HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and
one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the
evaporator core surface.
10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the
tool. Be sure to spray warm water through the
nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it
will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and
rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged ,
the Cooling Coil Coating will not flow through the applicator tool.
11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system
operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from
underneath the vehicle. 15. Reinstall the cabin air filter if necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Fuse: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From
(HVAC) System > Page 1379
Parts Information
Important The Cooling Coil Coating listed below is the only GM approved product for use under
warranty as an evaporator core disinfectant and for the long term control of evaporator core
microbial growth.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Fuse: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From
(HVAC) System > Page 1385
3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air
filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product
may clog the filter. If the
cabin air filter appears to have little or no remaining life, suggest a replacement to your customer.
5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE
COOLING COIL COATING INTO THE
BLOWER MOTOR COOLING TUBE.
6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line
operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well.
Screw the bottle onto the cap on the applicator tool's pick-up tube.
Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil
slightly in the bottom of a 120 ml (4 oz) bottle.
8. Use one of the following three methods to apply the Cooling Coil Coating.
Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil
Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)).
Application Through Blower Motor Control Module Opening
- Remove the blower motor control module (blower motor resistor). Refer to the applicable
procedure in SI.
- Clean any debris or foreign material from inside the HVAC module and on the evaporator core
surface.
- Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower
motor control module (blower motor resistor) opening.
- Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and
surrounding gasket surfaces.
- When the application is complete, install the blower motor blower motor control module (blower
motor control module).
Application Through Blower Motor Opening
- Remove the blower motor. Refer to the applicable blower motor removal procedure in SI.
- Clean any debris or foreign material from inside the HVAC module and on the evaporator core
surface.
- Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening.
- Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and
surrounding gasket surfaces.
- When the application is complete, install the blower motor.
Application Through a Hole in the HVAC Module
- If neither of the two previous application methods are available, it may be necessary to drill a hole
in the HVAC module.
- Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10
mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and
the blower motor fan.
- With the air distribution vents closed and the blower motor fan speed on HIGH, insert the
applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the
evaporator core.
- Use a GM approved RTV sealant to plug the hole in the HVAC module.
9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately
10 minutes, with the compressor disabled,
HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and
one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the
evaporator core surface.
10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the
tool. Be sure to spray warm water through the
nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it
will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and
rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged ,
the Cooling Coil Coating will not flow through the applicator tool.
11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system
operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from
underneath the vehicle. 15. Reinstall the cabin air filter if necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Fuse: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From
(HVAC) System > Page 1386
Parts Information
Important The Cooling Coil Coating listed below is the only GM approved product for use under
warranty as an evaporator core disinfectant and for the long term control of evaporator core
microbial growth.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Engine Compartment Fuse Block
Fuse: Locations Engine Compartment Fuse Block
ENGINE COMPARTMENT FUSE BLOCK
The engine compartment fuse block is located on the driver side of the engine compartment.
To remove the cover, push in on the tab on the end of the cover and lift. To reinstall the cover, line
up the tab and push down on the cover until the tab clicks into place.
Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the
covers on any electrical component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Engine Compartment Fuse Block > Page 1389
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Engine Compartment Fuse Block > Page 1390
The trailer brake relay is located on the bottom side of the battery harness.
FUSES .................................................................................................................................................
..................................................................... USAGE
O2 SNSR ..........................................................................................................................................
Oxygen Sensors, Air Injection Reactor (AIR) Relay A/C
..............................................................................................................................................................
Air Conditioning Control Head, Power Seats A/C CMPRSR ...............................................................
...................................................................................................... Air Conditioning Compressor ABS
.................................................................................................... Antilock Brake System (ABS), ABS
Module, Four-Wheel Drive, Gravity Sensor ABS 1 ..............................................................................
................................................................................................................... ABS 1 (ABS Logic) ABS 2
..............................................................................................................................................................
................................... ABS 2 (ABS Pump) AUX PWR 1 .....................................................................
................................................................................................................... Accessory Power 1 AUX
PWR 2 .................................................................................................................................................
....................................... Accessory Power 2 BCK/UP .......................................................................
.............................................................................................................................. Back-up Lights
BLWR ..................................................................................................................................................
.............................................. Climate Control Fan CLSTR .................................................................
...................................................................................................................................................
Cluster CNSTR VENT .........................................................................................................................
............................................. Fuel Canister Vent Solenoid CRUISE ...............................................
Cruise Control Switch, Inside Rearview Mirror, Transfer Case Control Module, Brake Switch, Clutch
Disable DR/LCK ..................................................................................................................................
....................................... Power Door Locks (If Equipped) DRL .........................................................
................................................................................................................................... Daylight
Running Lamps ERLS .......................................................................................... Mass Air Flow
(MAF) Sensor, Can Purge Solenoid, Air Injector Reactor (AIR) Relay ETC .......................................
...................................................................................................................................... Electronic
Throttle Control (ETC) FOG/LAMP ......................................................................................................
......................................................................... Fog Lamps (If Equipped) FRT PRK LAMP
....................................................................... Front Park/Turn Lamps, Driver and Passenger Side
Power Window Switches Lighting FRT/AXLE .....................................................................................
.................................................................................................... Front Axle Actuator FSCM ..............
..............................................................................................................................................................
....... Fuel System Control Module BACKUP LAMP .............................................................................
............................................................................................................ Backup Lamp HORN ..............
..............................................................................................................................................................
............................................ Horn HTD/SEAT .....................................................................................
.......................................................................................... Heated Seat (If Equipped) IGN
........................................................... Ignition, Clutch Starter Switch, Neutral Safety Back-Up
Switch, Ignition Coils 1-5, Air Conditioning Relay INJ .........................................................................
............................................................................................................................................... Injectors
LT HDLP ..............................................................................................................................................
.......................................... Driver Side Headlamp PCM B ..................................................................
......................................................................................................... Power Control Module (PCM) B
PCMI ....................................................................................................................................................
............................. Power Control Module (PCM) PWR/SEAT
......................................................................................................................................................
Power Seat Circuit Breaker (If Equipped) PWR/WNDW .....................................................................
............................................................................................... Power Windows (If Equipped) RDO ....
..............................................................................................................................................................
........................................................ Radio REAR PRK LAMP
.............................................................................................. Rear Parking Lamp 1, Passenger Side
Taillamp, License Plate Lamps REAR PRK LAMP2 ................ Driver Side Rear Taillamp,
Passenger Side Airbag Indicator Lighting, Instrument Panel Dimming Power (2WD/4WD
switch lighting)
RT HDLP .............................................................................................................................................
..................................... Passenger Side Headlamp RVC ...................................................................
...................................................................................................................... Regulated Voltage
Control S/ROOF ..................................................................................................................................
........................................................ Sunroof (If Equipped) STOP .......................................................
........................................................................................................................................................
Stop Lamps STRTR ............................................................................................................................
............................................................... Starter Solenoid Relay TBC ................................................
............................................................................................................................................... Truck
Body Controller TCM ...........................................................................................................................
........................................................ Transmission Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Engine Compartment Fuse Block > Page 1391
TCCM ..................................................................................................................................................
.............................. Transfer Case Control Module TRAILER BRAKE ................................................
....................................................................................................................................... Trailer Brake
TRANS ................................................................................................................................................
.......................................... Transmission Solenoid TRN/HAZRD FRT
.....................................................................................................................................
Turn/Hazard/Courtesy/Cargo Lamps/Mirrors TRN/HAZRD REAR ......................................................
............................................................................................................ Rear Turn/Hazard Lights
VSES ...................................................................................................................................................
................. Vehicle Stability Enhancement System WPR ....................................................................
.....................................................................................................................................................
Wiper WSW .........................................................................................................................................
...................................................... Wiper/Washer Switch
RELAYS ..............................................................................................................................................
.................................................................... USAGE
A/C CMPRSR ......................................................................................................................................
............................... Air Conditioning Compressor BEAM SEL ............................................................
................................................................................................................................... Beam Selection
DRL .....................................................................................................................................................
....................................... Daylight Running Lamps FOG/LAMP ..........................................................
..................................................................................................................... Fog Lamps (If Equipped)
BK UP LP ............................................................................................................................................
...................................................... Back Up Lamp HDLP ...................................................................
............................................................................................................................................
Headlamps HORN ...............................................................................................................................
......................................................................................... Horn IGN 3 HVAC
................................................................................................. Ignition 3, Climate Control, Climate
Control Head Fuse, Power Seat Fuse PRK/LAMP
............................................................................................................................................. Front
Parking Lamp Fuse, Rear Parking Lamps PWR/TRN
................................................................................................................ Powertrain, Electronic
Throttle Control Fuse, Oxygen Sensor Fuse RAP
................................................................................ Retained Accessory Power (Power Window
Fuse, Wiper/Washer Switch Fuse), Sunroof Fuse RUN/CRNK ............ Run/Crank, Airbag System
Fuse, Cruise Control Fuse, Ignition Fuse, Back-Up Lamps, ABS Fuse, Front Axle, PCM-1, Injectors
Fuse, Transmission Fuse, ERLS
STRTR .................................................................................................................................................
................................... Starter Relay (PCM Relay) VSES ...................................................................
................................................................................................. Vehicle Stability Enhancement
System WPR .......................................................................................................................................
................................................................. Wipers (On/Off) WPR 2 .....................................................
.......................................................................................................................................... Wiper 2
(High/Low)
MISCELLANEOUS ..............................................................................................................................
................................................................. USAGE
A/C CLTCH ..........................................................................................................................................
....................... Diode -- Air Conditioning, Clutch MEGA FUSE ...........................................................
......................................................................................................................................... Mega Fuse
WPR ....................................................................................................................................................
....................................................... Diode -- Wiper
FUSES .................................................................................................................................................
..................................................................... USAGE
Fuse A .................................................................................................................................................
.................................................. Trailer Park Lamp Fuse B .................................................................
.......................................................................................................... Communication Interface
Module Fuse C .......................................................................................................... Supplemental
Inflatable Restraint System, Sensing and Diagnostic Module Fuse D ................................................
................................................................................................................................... Trailer Auxiliary
Maxi-Fuse
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Engine Compartment Fuse Block > Page 1392
Fuse: Locations Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Engine Compartment Fuse Block > Page 1393
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Engine Compartment Fuse Block > Page 1394
Fuse Block - Underhood - Top View
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Engine Compartment Fuse Block > Page 1395
Fuse Block - Underhood - Bottom View
Fuse Block - Underhood X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Fuse Block - Underhood X2
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Fuse Block - Underhood X4
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Fuse Block - Underhood X5
Fuse Block - Underhood X6
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Fuse Block - Underhood X7
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Fuse Block - Underhood X9
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Fuse: Application and ID
Electrical Center Identification Views
Fuse Block - Underhood Label
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Fuse Block - Underhood - Top View
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Fuse Block - Underhood - Bottom View
Fuse Block - Underhood X1
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Fuse Block - Underhood X2
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Fuse Block - Underhood X4
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Fuse Block - Underhood X5
Fuse Block - Underhood X6
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Fuse Block - Underhood X7
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Fuse Block - Underhood X9
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Locations > Harness Routing Views
Fuse Block: Locations Harness Routing Views
Harness Routing Views
Forward Lamp Harness Routing
1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn
Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right
11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low
Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body
Harness) 16 - X103 (Forward Lamp Harness to Body Harness)
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17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness
(TT5) 19 - Forward Lamp Harness (-TT5)
Battery Cable Harness Routing
1 - G104 2 - Starter 3 - Generator X2 4 - Battery 5 - G100 6 - Battery Negative Terminal 7 - Fuse
Block - Underhood 8 - Ring Terminal Battery 9 - Ring Terminal Generator 10 - Battery Positive
Terminal 11 - Generator
Body Harness Routing 1 of 3 (Regular Cab)
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1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18
- Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
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Locations > Harness Routing Views > Page 1424
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C
Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
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Locations > Harness Routing Views > Page 1425
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Locations > Harness Routing Views > Page 1426
Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Side of the Engine Compartment Components
1 - G104 2 - Starter 3 - Battery 4 - G100 5 - Fuse Block - Underhood 6 - Battery Positive Terminal 7
- Generator
Left and Right Sides of Engine Compartment Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Locations > Harness Routing Views > Page 1427
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield
Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Fuse Block: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
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Diagrams > Diagram Information and Instructions > Page 1596
Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
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1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
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Fuse Block: Service and Repair
Underhood Electrical Center or Junction Block Replacement
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
2. Press tabs (1) inward and lift to remove the junction block cover. 3. Remove the fuse relay
center bolts (3) and remove the fuse relay center from the junction block bracket. 4. Pull downward
on the wiring harness ends to remove from the bottom of the fuse relay center.
Installation Procedure
1. Align the wiring harnesses and install the fuse relay center (3).
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Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the fuse relay center bolts.
Tighten the relay center bolts to 6 Nm (53 lb in).
3. Install the junction block cover (2). Press downward to engage the tabs.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips
Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System
Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1608
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
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^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1610
Customer TPMS Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1611
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1612
Frequently Asked Questions
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Service and Repair
Maintenance Required Lamp/Indicator: Service and Repair
SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR
If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON"
indicator. This indicator is not a maintenance indicator and does not mean a maintenance service
is required.
For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information
refer to Malfunction Indicator Lamp.
For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Testing and Inspection
Malfunction Indicator Lamp: Testing and Inspection
Malfunction Indicator Lamp (MIL) Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category.
Circuit/System Description
Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module
(ECM) turns the MIL ON by grounding the MIL control circuit.
Reference Information Schematic Reference
* Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges
and Warning Indicators/System Diagram/Instrument Cluster Schematics)
* Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams)
Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning)for scan
tool information
Circuit/System Verification
Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool.
Circuit/System Testing
1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition
ON, verify that a test lamp illuminates between the ignition circuit and ground.
‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high
resistance. If the circuit tests normal and the
ignition circuit fuse is open, replace the IPC.
3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON
and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the
commanded states.
‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests
normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to
voltage or an open/high resistance. If the circuit tests normal, replace the
ECM.
5. If all circuits test normal, replace the IPC.
Repair Instructions
Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Verification Tests and Procedures) after completing the diagnostic procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Testing and Inspection > Page 1619
* Instrument Cluster Replacement (See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement)
* Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM
replacement, setup, and programming
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
GM Oil Life System Resetting
The vehicle has a computer system that has a change engine oil message, indicating when to
change the engine oil and filter. This is based on engine revolutions and engine temperature, and
not on mileage. Based on driving conditions, the kilometers or mileage at which an oil change will
be indicated can vary considerably. For the oil life system to work properly, the system must be
reset every time the oil is changed.
When the system has calculated that oil life has been diminished, it will indicate that an oil change
is necessary. The change engine oil message will come on. The oil must be changed as soon as
possible. It is possible that, if the vehicle is driven under the best conditions, the oil life system may
not indicate that an oil change is necessary for over a year. However, the engine oil and filter must
be changed at least once a year and at this time the system must be reset. If the system is ever
reset accidentally, the oil must be changed at 3,000 miles (5 000 km) since the last oil change.
Remember to reset the oil life system whenever the oil and filter is changed.
Resetting Procedure
1. Turn the ignition to RUN with the engine OFF. 2. Press and release the reset stem in the lower
center of the instrument panel (I/P) cluster until the OIL LIFE message is displayed. 3. Once the
alternating OIL LIFE and RESET messages appears in the display, press and hold the reset stem
until several beeps sound. This confirms
the OIL LIFE system has been reset.
4. Turn the key to lock.
If the CHANGE OIL message comes back on when you start the engine, the ENGINE OIL LIFE
system has not reset. Repeat the procedure.
Alternate Method
1. Turn the ignition key to RUN with the engine off. 2. Fully press the release the accelerator pedal
3 times within 5 seconds. Several beeps sound. This confirms the oil life system has been reset. 3.
If the CHANGE/OIL message comes back on when you start the engine, the engine oil life system
has not been reset. Repeat the procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and
Repair
Vehicle Lifting: Service and Repair
Lifting and Jacking the Vehicle
Danger: To avoid any vehicle damage, serious personal injury or death when major components
are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack
stands at the opposite end from which the components are being removed and strap the vehicle to
the hoist.
Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands
to support the vehicle when lifting the vehicle with a jack.
Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
Vehicle Lifting
* Ensure that the lifting equipment meets weight requirements and is in good working order. Always
follow the lift manufacturer's instructions.
* You may lift and support the front of the vehicle at the front suspension near the wheel
assemblies. Ensure that the arms of the front cradle are extended as close to the steering knuckle
as possible.
* Ensure that the vehicle is centered on the hoist before attempting to lift.
* When using a suspension-contact hoist, ensure that the rear cradle has adequate clearance for
the rear stabilizer bar.
* When lifting or jacking a vehicle, be certain that the lift pads do not contact the exhaust system,
brake pipes, cables, HVAC lines, wiring harnesses, fuel lines, or underbody. Such contact may
result in damage or unsatisfactory vehicle performance.
* When using a frame-contact hoist, only place the pads on flat surfaces. Do not place pads within
50 mm (2 in) of any radius.
* Before lifting the vehicle, verify that the vehicle loads are secure and equally distributed.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and
Repair > Page 1627
* When major components are removed from the vehicle when supported on a hoist, support the
vehicle with jack stands at the opposite end from which the components are being removed and
secure the vehicle frame to the hoist pads nearest the component to be removed.
Vehicle Jacking
* Park the vehicle on a clean, hard, level surface before jacking the vehicle.
* Any time you lift the vehicle on one end, chock the wheels at the opposite end.
* Use jack stands in order to provide support.
* When supporting the vehicle using jack stands, place the jack stands under the side rails or the
axle.
* When lifting under the rear differential, do not allow the jack pad to contact the rear stabilizer bar
or mounting hardware.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM
Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 1642
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 1643
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 1644
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 1645
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 1646
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement
Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and
Wheel Removal and Installation (See: Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service
and Repair/Removal and Replacement).
Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the
inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 Nm (62 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page
1649
Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting.
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and
Repair/Removal and Replacement).
Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor
unique identification code cannot be learned into the body control module (BCM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensors internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire
Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page
1650
Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement
Tire Valve Stem Grommet Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and
Wheel Removal and Installation (See: Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting:
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead
from the wheel.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the outside of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service
and Repair/Removal and Replacement).
Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure
Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all
residual liquid sealant from the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the
sensor grommet from the valve stem.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor
valve stem.
3. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page
1651
4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 Nm (62 lb in).
Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and
Repair/Removal and Replacement). 6. Install the tire/wheel assembly on the vehicle. Refer to Tire
and Wheel Removal and Installation (See: Service and Repair). 7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips
Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System
Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
1657
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
1658
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
1659
Customer TPMS Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
1660
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
1661
Frequently Asked Questions
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor
Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor
Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1674
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
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Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
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5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
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Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1677
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
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Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1678
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement
Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and
Wheel Removal and Installation (See: Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service
and Repair/Removal and Replacement).
Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the
inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 Nm (62 lb in).
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 1681
Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting.
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and
Repair/Removal and Replacement).
Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor
unique identification code cannot be learned into the body control module (BCM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensors internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire
Pressure Indicator Sensor Learn (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 1682
Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement
Tire Valve Stem Grommet Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and
Wheel Removal and Installation (See: Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting:
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead
from the wheel.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the outside of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service
and Repair/Removal and Replacement).
Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure
Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all
residual liquid sealant from the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the
sensor grommet from the valve stem.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor
valve stem.
3. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 1683
4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 Nm (62 lb in).
Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and
Repair/Removal and Replacement). 6. Install the tire/wheel assembly on the vehicle. Refer to Tire
and Wheel Removal and Installation (See: Service and Repair). 7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service
and Repair
Spare Tire: Service and Repair
Spare Tire Carrier Replacement
Removal Procedure
1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover
on the bumper and use the ignition key to remove
the lock.
Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools.
The use of air tools at high speeds will damage the spare tire hoist assembly.
2. Turn the hoist shaft counterclockwise to lower the spare tire to the ground. Continue to turn the
hoist shaft until the spare tire can be pulled out
from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary
latch is engaged causing the tire not to lower.
3. If the secondary latch is engaged and the cable end is visible, perform the following procedure:
1. Tighten the cable by turning the hoist shaft clockwise until you hear two clicks or feel it skip
twice. You cannot overtighten the cable. 2. Loosen the cable by turning the hoist shaft
counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the
spare tire can be removed. 4. If the spare tire cannot be lowered, turn the hoist shaft
counterclockwise until approximately 15 cm (6 in) of cable is exposed. 5. Raise and support the
vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 6. Place
a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission
jack under the secondary latch release button at the center of the spare tire. Arrange the arms of
the
transmission jack so they will support the tire after it has been released.
8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the
secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, turn the hoist shaft
counterclockwise until the tire is low enough to remove.
4. If the secondary latch is engaged and the cable end is not visible, perform the following
procedure:
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Place a transmission jack, or equivalent, under the spare tire. 3.
Position the center of the transmission jack under the secondary latch release button at the center
of the spare tire. Arrange the arms of the
transmission jack so they will support the tire after it has been released.
4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the
secondary latch. 5. Lower the tire and remove it from the jack.
5. Raise and support the vehicle if it is not already raised. Refer to Lifting and Jacking the Vehicle
(See: Vehicle Lifting/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service
and Repair > Page 1688
6. Remove the spare tire hoist guide mounting bolt from the crossmember. 7. Remove the spare
tire hoist shaft guide.
8. Remove the bolt. 9. Remove the hoist from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service
and Repair > Page 1689
1. Install the hoist.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt and tighten to 40 Nm (30 lb ft).
3. Install the spare tire hoist shaft guide. 4. Install the mounting bolt for the guide and tighten to 30
Nm (20 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service
and Repair > Page 1690
5. Install the spare tire to the hoist.
Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools.
The use of air tools at high speeds will damage the spare tire hoist assembly.
6. Turn the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it
skips twice. You cannot overtighten the cable. 7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV)
Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV)
INFORMATION
Bulletin No.: 00-03-10-006F
Date: May 04, 2010
Subject: Information on Tire Radial Force Variation (RFV)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009
and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION
Supercede: This bulletin is being revised to considerably expand the available information on
Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin
Number 00-03-10-006E (Section 03 - Suspension).
Important
- Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven
a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin
Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires.
- Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel
assemblies for each vehicle.
The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation
measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable
tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force
variation is highway speed shake on smooth roads.
Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out
of round and tire force variation. These three conditions are not necessarily related. All three
conditions must be addressed.
Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle,
two plane dynamic wheel balancers are readily available and can accurately correct any
imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer,
and proper balance weights, are all factors required for a quality balance. However, a perfectly
balanced tire/wheel assembly can still be "oval shaped" and cause a vibration.
Before balancing, perform the following procedures.
Tire and Wheel Diagnosis
1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are
centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while
shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick.
3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and
correct as necessary:
- Missing balance weights
- Bent rim flange
- Irregular tire wear
- Incomplete bead seating
- Tire irregularities (including pressure settings)
- Mud/ice build-up in wheel
- Stones in the tire tread
- Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to
diagnosing a smooth road shake condition.
4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a
sufficient distance on a known, smooth road
surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes
are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section
of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration
as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order
(one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high
enough in frequency that most humans can start to hear them at highway speeds, but are too high
to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment.
If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a
throbbing), chances are good that the vehicle could have driveline vibration. This type
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1699
of vibration is normally felt more in the "seat of the pants" than the steering wheel.
5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found
at the end of this bulletin. This should be done
after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to
eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency
is prior to vehicle service and documents the amount of improvement occurring as the result of the
various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required.
A copy of the completed worksheet must be saved with the R.O. and a copy included with any
parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically
indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number
08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if
this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away
and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration
may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if
vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire
flat-spotting can be ruled out as the cause for vibration.
6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle
being parked for long periods of time and that the
nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information
on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment
Tires.
7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel
assembly on a known, calibrated, off-car dynamic
balancer.Make sure the mounting surface of the wheel and the surface of the balancer are
absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and
always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is
not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim
flange, remove all balance weights and rebalance to as close to zero as possible. If you can see
the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the
wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First
order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or
hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough,
it can be seen.
If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and
force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700
can address both (it is also a wheel balancer).
Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will
produce in one revolution under a constant load. Radial force variation is what the vehicle feels
because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not
under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel
assembly runout be within specification.
Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures
radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV
measurement at this point. To isolate the wheel, its runout must be measured. This can be easily
done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout
specification, the tire's RFV can then be addressed.
After measuring the tire/wheel assembly under load, and the wheel alone, the machine then
calculates (predicts) the radial force variation of the tire. However, because this is a prediction that
can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in
tire production, this type of service equipment should NOT be used to audit new tires. Rather, it
should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel
assembly.
Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of
finding the low point of the wheel (for runout) and the high point of the tire (for radial force
variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly
force variation.
The machine will simplify this process into easy steps. The following assembly radial force variation
numbers should be used as a guide:
When measuring RFV and match mounting tires perform the following steps.
Measuring Wheel Runout and Assembly Radial Force Variation
Important The completed worksheet at the end of this bulletin must be attached to the hard copy of
the repair order.
- Measure radial force variation and radial runout.
- If a road force/balancing machine is used, record the radial force variation (RFV) on the
worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the
front left corner. If the machine is not available and the EVA data suggests there is an issue, swap
the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem
still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those
tires onto the subject vehicle.
- If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the
worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040
in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive
customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to
have the lowest runout assembly to the front left corner. If the machine is not available and the
EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the
back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do
not exhibit the same frequency and swap those tires
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1700
onto the subject vehicle.
- After match mounting, the tire/wheel assembly must be rebalanced.
If match mounting tires to in-spec wheels produces assembly values higher than these, tire
replacement may be necessary. Replacing tires at lower values will probably mean good tires are
being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect
force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring.
Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to
measuring.
Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are
more sensitive, and may require lower levels. Also, there are other tire parameters that equipment
such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be
contacted for further instructions.
Important
- When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's
center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are
secondary. Usually a back cone method to the machine should be used. For added accuracy and
repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This
system is offered by all balancer manufacturers in GM's dealer program.
- Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT
recommended, and may void the tire warranty. However, tires may have been ground by the tire
company as part of their tire manufacturing process. This is a legitimate procedure.
Steering Wheel Shake Worksheet
When diagnosing vibration concerns, use the following worksheet in conjunction with the
appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1701
Refer to the appropriate section of SI for specifications and repair procedures that are related to the
vibration concern.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels
Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels
TECHNICAL
Bulletin No.: 05-03-10-003F
Date: April 27, 2010
Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels
Supercede: This bulletin is being revised to update the model years and the bulletin reference
information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension).
Condition
Some customers may comment on a low tire pressure condition.
Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel.
Cause
Porosity in the cast aluminum wheel may be the cause.
Notice
This bulletin specifically addresses issues related to the wheel casting that may result in an air
leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin
Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light
Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat).
Correction
1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service
procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the
tire/wheel assembly in a water bath, or use a spray bottle with soap
and water to locate the specific leak location.
Important
- If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim),
the wheel should be replaced.
- If two or more leaks are located on one wheel, the wheel should be replaced.
3. If air bubbles are observed, mark the location.
- If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks.
- If the leak is located on the aluminum wheel area, continue with the next step.
4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the
wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove
the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the
INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose
cleaner, such as 3M(R) General Purpose
Adhesive Cleaner, P/N 08984, or equivalent.
8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use
88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry.
Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging
the repair area may result in an air leak.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels >
Page 1706
10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire
Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on
the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and
inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the
tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire
and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty
one tube of adhesive/sealant per wheel repair.
For vehicles repaired under warranty, use:
One leak repair per wheel.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON
Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON
TECHNICAL
Bulletin No.: 08-03-10-006C
Date: April 27, 2010
Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated,
Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat)
Models:
2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 08-03-10-006B (Section 03 - Suspension).
Condition
Some customers may comment on a tire that slowly loses air pressure over a period of days or
weeks.
Cause
Abrasive elements in the environment may intrude between the tire and wheel at the bead seat.
There is always some relative motion between the tire and wheel (when the vehicle is driven) and
this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear
continues, there may also be intrusion at the tire/wheel interface by corrosive media from the
environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may
appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be
visible until the tire is dismounted from the wheel.
Notice
This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in
an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please
refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum
Wheels (Repair with Adhesive Sealant)
Correction
In most cases, this type of air loss can be corrected by following the procedure below.
Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to
repair the wheel with the procedure below.
Notice
The repair is no longer advised or applicable for chromed aluminum wheels.
1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and
Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to
be around the bead seat of the wheel, dismount the tire to examine
the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat
Corrosion
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON >
Page 1711
Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel
flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for
additional information on possible wheel porosity issues.
3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a
rough or uneven surface that is difficult for the tire to
maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel
that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion
4. If corrosion is found on the wheel bead seat, measure the affected area as shown below.
- For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of
repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
- For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area
of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the
corrosion and any flaking paint. You should
remove the corrosion back far enough until you reach material that is stable and firmly bonded to
the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges
that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired
surface.
Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be
visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not
visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend
to the visible surfaces on the FACE of the wheel, that wheel must be replaced.
Important Remove ONLY the material required to eliminate the corrosion from the bead seating
surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as
smooth and level as possible.
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Page 1712
Acceptably Prepared (Cleaned-Up) Wheel Surface
6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially
available tire sealant such as Patch Brand Bead
Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will
permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this
sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat
7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel
Removal and Installation in SI.
Parts Information
Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at
www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
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Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON >
Page 1713
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion
INFORMATION
Bulletin No.: 00-03-10-002F
Date: April 21, 2011
Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum
Wheels
Models:
2012 and Prior GM Cars and Trucks
Supercede: This bulletin is being revised to update model years, suggest additional restorative
products and add additional corrosion information. Please discard Corporate Bulletin Number
00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the
customer.
What is Chemical Staining of Chrome Wheels? Figure 1
Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an
example). These stains are frequently milky, black, or greenish in appearance. They result from
using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient
to clean wheels.
If the customer insists on using a wheel cleaner they should only use one that specifically states
that it is safe for chromed wheels and does not contain anything in the following list. (Dealers
should also survey any products they use during prep or normal cleaning of stock units for these
chemicals.)
- Ammonium Bifluoride (fluoride source for dissolution of chrome)
- Hydrofluoric Acid (directly dissolves chrome)
- Hydrochloric Acid (directly dissolves chrome)
- Sodium Dodecylbenzenesulfonic Acid
- Sulfamic Acid
- Phosphoric Acid
- Hydroxyacetic Acid
Notice
Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most
customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal.
Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the
paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car
warranty. Soap and water applied with a soft brush is usually all that is required to clean the
calipers.
Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean,
clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts,
lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to
the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the
damage around and under the wheel weight where the cleaner was incompletely flushed away.
Notice
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Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 1719
Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome
wheels (or any wheels).
If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be
avoided.
For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and
Instructions below.
Warranty of Stained Chrome Wheels
Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome
wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were
returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be
charged back to the dealership. To assist the customer, refer to Customer Assistance and
Instructions below.
Pitting or Spotted Appearance of Chrome Wheels Figure 2
A second type or staining or finish disturbance may result from road chemicals, such as calcium
chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to
Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be
uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels
should be washed with mild soap and water and thoroughly rinsed as soon as conveniently
possible.
Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can
also stain chrome wheels. The staining will look like small pitting. This staining will usually be on
the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward
direction while being splashed by the road chemical. If a vehicle must be operated under such
conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed
as soon as conveniently possible.
Warranty of Pitted or Spotted Chrome Wheels
Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time.
Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish
and may cause damage if the wheels are not kept clean.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean if they are operating the vehicle in an area that
applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior
approval by the District Manager - Customer Care and Service Process (DM-CCSP).
"Stardust" Corrosion of Chrome Wheels Figure 3
A third type of finish disturbance results from prolonged exposure to brake dust and resultant
penetration of brake dust through the chrome. As brakes are applied hot particles of brake material
are thrown off and tend to be forced through the leading edge of the wheel spoke windows by
airflow. These
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Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 1720
hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed
to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the
chrome leaving a pit or small blister in the chrome.
Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and
Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up
or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars
Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be
waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax
#M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake
dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may
be used. It will clean and shine the chrome and leave behind a wax coating that may help protect
the finish.
Warranty of Stardust Corroded Chrome Wheels
Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be
replaced one time.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust
build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care
and Service Process (DM-CCSP).
Customer Assistance and Instructions
GM has looked for ways customers may improve the appearance of wheels damaged by acidic
cleaners. The following product and procedure has been found to dramatically improve the
appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the
following:
Notice
THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN
EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE
APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL
REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED
INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER,
EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS
EXACTLY.
1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce
wheel staining. Flood all areas of the wheel with water
to rinse.
2. Dry the wheels completely.
Notice Begin with a small section of the wheel and with light pressure buff off polish and examine
results. ONLY apply and rub with sufficient force and time to remove enough staining that you are
satisfied with the results. Some wheels may be stained to the extent that you may only achieve a
50% improvement while others may be able to be restored to the original lustre. IN ALL CASES,
only apply until the results are satisfactory.
3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the
polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the
towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If
continued applications fail to improve the appearance
further discontinue use.
This procedure will improve the appearance of the wheels and may, with repeated applications,
restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above
procedure may marginally improve the condition but will not restore the finish or remove the pitting.
In this type of staining the wheel finish has actually been removed in spots and no manner of
cleaning will restore the finish.
†*We believe this source and their products to be reliable. There may be additional manufacturers
of such products/materials. General Motors does not endorse, indicate any preference for or
assume any responsibility for the products or material from this firm or for any such items that may
be available from other sources.
Parts Information
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Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 1721
*This product is currently available from 3M. To obtain information for your local retail location
please call 3M at 1-888-364-3577.
**This product is currently available from Meguiars (Canada). To obtain information for your local
retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com.
^ This product is currently available from Tri-Peek International. To obtain information for your local
retail location please call Tri-Peek at
1-877-615-4272 or at www.tripeek.com.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum
Wheels
Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels
INFORMATION
Bulletin No.: 99-08-51-007E
Date: March 17, 2011
Subject: Refinishing Aluminum Wheels
Models:
2012 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add additional model years. Please discard Corporate
Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories).
This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not
endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic
refinishing of the wheel's coatings, using recommended procedures, is allowed.
Evaluating Damage
In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion,
scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be
sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the
wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been
refinished by an outside company must be returned to the same vehicle. The Dealer must record
the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to
Refinisher's Responsibility - Outside Company later in this bulletin.
Aluminum Wheel Refinishing Recommendations
- Chrome-plated aluminum wheels Re-plating these wheels is not recommended.
- Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the
clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be
performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later
in this bulletin.
- Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat
procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original
coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum
Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel.
- Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them.
In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is
possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel
should be resurfaced by using a sanding process rather than a machining process. This allows the
least amount of material to be removed.
Important Do not use any re-machining process that removes aluminum. This could affect the
dimensions and function of the wheel.
Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will
better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM
recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle
SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using
any of the painting options, it is recommended that all four wheels be refinished in order to maintain
color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures
and product recommendations.
Refinisher's Responsibility - Outside Company
Important Some outside companies are offering wheel refinishing services. Such refinished wheels
will be permanently marked by the refinisher and are warranted by the refinisher. Any process that
re-machines or otherwise re-manufactures the wheel should not be used.
A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent.
Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is
allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to
assure that the same wheel is returned. A plastic media blast may be used for clean up of the
wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed.
Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed.
Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel
mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel
and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the
new vehicle warranty, whichever is
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Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum
Wheels > Page 1726
longer.
Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact
surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut
torque.
When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to
reduce the chance of future cosmetic damage.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions
Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions
INFORMATION
Bulletin No.: 06-03-10-010A
Date: June 09, 2010
Subject: Information on Proper Wheel Changing Procedures and Cautions
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab
9-7X 2005-2009 Saturn Vehicles
Attention:
Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel
Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and
reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel
installation. Always refer to SI for wheel lug nut torque specifications and complete jacking
instructions for safe wheel changing.
Supercede: This bulletin is being revised to include the 2011 model year and update the available
special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension).
Frequency of Wheel Changes - Marketplace Driven
Just a few years ago, the increasing longevity of tires along with greater resistance to punctures
had greatly reduced the number of times wheels were removed to basically required tire rotation
intervals. Today with the booming business in accessory wheels/special application tires (such as
winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more
than ever. With this increased activity, it opens up more of a chance for error on the part of the
technician. This bulletin will review a few of the common concerns and mistakes to make yourself
aware of.
Proper Servicing Starts With the Right Tools
The following tools have been made available to assist in proper wheel and tire removal and
installation.
- J 41013 Rotor Resurfacing Kit (or equivalent)
- J 42450-A Wheel Hub Resurfacing Kit (or equivalent)
Corroded Surfaces
One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle.
Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened
wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed
away from water splash. This action may result in clearance at the mating surface of the wheel and
an under-torqued condition.
Caution
Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or
brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting
surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is
moving, possibly resulting in a loss of control or personal injury.
Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If
corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding
pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating
surface.
The J 41013 (or equivalent) can be used to clean the following surfaces:
- The hub mounting surface
- The brake rotor mounting surface
- The wheel mounting surface
Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub.
Lubricants, Grease and Fluids
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Procedures/Precautions > Page 1731
Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in
removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to
installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper
readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY.
Notice
Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or
drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to
clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light
coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel
pilot hole to prevent wheel seizure to the axle or bearing hub.
Wheel Stud and Lug Nut Damage
Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse.
You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not
retain properly, yet give the impression of fully tightening. Always inspect and replace any
component suspected of damage.
Tip
Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged
BEFORE tightening the nut.
Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side
of the tire is pointing in the direction of forward rotation.
Wheel Nut Tightening and Torque
Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid
additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown
for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in
order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off
center resulting in vibration.
The Most Important Service You Provide
While the above information is well known, and wheel removal so common, technicians run the risk
of becoming complacent on this very important
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Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
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service operation. A simple distraction or time constraint that rushes the job may result in personal
injury if the greatest of care is not exercised. Make it a habit to double check your work and to
always side with caution when installing wheels.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force
Variation (RFV)
Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV)
INFORMATION
Bulletin No.: 00-03-10-006F
Date: May 04, 2010
Subject: Information on Tire Radial Force Variation (RFV)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009
and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION
Supercede: This bulletin is being revised to considerably expand the available information on
Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin
Number 00-03-10-006E (Section 03 - Suspension).
Important
- Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven
a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin
Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires.
- Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel
assemblies for each vehicle.
The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation
measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable
tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force
variation is highway speed shake on smooth roads.
Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out
of round and tire force variation. These three conditions are not necessarily related. All three
conditions must be addressed.
Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle,
two plane dynamic wheel balancers are readily available and can accurately correct any
imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer,
and proper balance weights, are all factors required for a quality balance. However, a perfectly
balanced tire/wheel assembly can still be "oval shaped" and cause a vibration.
Before balancing, perform the following procedures.
Tire and Wheel Diagnosis
1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are
centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while
shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick.
3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and
correct as necessary:
- Missing balance weights
- Bent rim flange
- Irregular tire wear
- Incomplete bead seating
- Tire irregularities (including pressure settings)
- Mud/ice build-up in wheel
- Stones in the tire tread
- Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to
diagnosing a smooth road shake condition.
4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a
sufficient distance on a known, smooth road
surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes
are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section
of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration
as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order
(one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high
enough in frequency that most humans can start to hear them at highway speeds, but are too high
to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment.
If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a
throbbing), chances are good that the vehicle could have driveline vibration. This type
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Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force
Variation (RFV) > Page 1737
of vibration is normally felt more in the "seat of the pants" than the steering wheel.
5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found
at the end of this bulletin. This should be done
after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to
eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency
is prior to vehicle service and documents the amount of improvement occurring as the result of the
various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required.
A copy of the completed worksheet must be saved with the R.O. and a copy included with any
parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically
indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number
08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if
this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away
and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration
may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if
vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire
flat-spotting can be ruled out as the cause for vibration.
6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle
being parked for long periods of time and that the
nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information
on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment
Tires.
7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel
assembly on a known, calibrated, off-car dynamic
balancer.Make sure the mounting surface of the wheel and the surface of the balancer are
absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and
always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is
not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim
flange, remove all balance weights and rebalance to as close to zero as possible. If you can see
the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the
wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First
order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or
hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough,
it can be seen.
If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and
force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700
can address both (it is also a wheel balancer).
Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will
produce in one revolution under a constant load. Radial force variation is what the vehicle feels
because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not
under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel
assembly runout be within specification.
Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures
radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV
measurement at this point. To isolate the wheel, its runout must be measured. This can be easily
done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout
specification, the tire's RFV can then be addressed.
After measuring the tire/wheel assembly under load, and the wheel alone, the machine then
calculates (predicts) the radial force variation of the tire. However, because this is a prediction that
can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in
tire production, this type of service equipment should NOT be used to audit new tires. Rather, it
should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel
assembly.
Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of
finding the low point of the wheel (for runout) and the high point of the tire (for radial force
variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly
force variation.
The machine will simplify this process into easy steps. The following assembly radial force variation
numbers should be used as a guide:
When measuring RFV and match mounting tires perform the following steps.
Measuring Wheel Runout and Assembly Radial Force Variation
Important The completed worksheet at the end of this bulletin must be attached to the hard copy of
the repair order.
- Measure radial force variation and radial runout.
- If a road force/balancing machine is used, record the radial force variation (RFV) on the
worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the
front left corner. If the machine is not available and the EVA data suggests there is an issue, swap
the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem
still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those
tires onto the subject vehicle.
- If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the
worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040
in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive
customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to
have the lowest runout assembly to the front left corner. If the machine is not available and the
EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the
back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do
not exhibit the same frequency and swap those tires
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force
Variation (RFV) > Page 1738
onto the subject vehicle.
- After match mounting, the tire/wheel assembly must be rebalanced.
If match mounting tires to in-spec wheels produces assembly values higher than these, tire
replacement may be necessary. Replacing tires at lower values will probably mean good tires are
being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect
force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring.
Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to
measuring.
Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are
more sensitive, and may require lower levels. Also, there are other tire parameters that equipment
such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be
contacted for further instructions.
Important
- When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's
center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are
secondary. Usually a back cone method to the machine should be used. For added accuracy and
repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This
system is offered by all balancer manufacturers in GM's dealer program.
- Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT
recommended, and may void the tire warranty. However, tires may have been ground by the tire
company as part of their tire manufacturing process. This is a legitimate procedure.
Steering Wheel Shake Worksheet
When diagnosing vibration concerns, use the following worksheet in conjunction with the
appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force
Variation (RFV) > Page 1739
Refer to the appropriate section of SI for specifications and repair procedures that are related to the
vibration concern.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast
Aluminum Wheels
Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels
TECHNICAL
Bulletin No.: 05-03-10-003F
Date: April 27, 2010
Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels
Supercede: This bulletin is being revised to update the model years and the bulletin reference
information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension).
Condition
Some customers may comment on a low tire pressure condition.
Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel.
Cause
Porosity in the cast aluminum wheel may be the cause.
Notice
This bulletin specifically addresses issues related to the wheel casting that may result in an air
leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin
Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light
Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat).
Correction
1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service
procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the
tire/wheel assembly in a water bath, or use a spray bottle with soap
and water to locate the specific leak location.
Important
- If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim),
the wheel should be replaced.
- If two or more leaks are located on one wheel, the wheel should be replaced.
3. If air bubbles are observed, mark the location.
- If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks.
- If the leak is located on the aluminum wheel area, continue with the next step.
4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the
wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove
the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the
INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose
cleaner, such as 3M(R) General Purpose
Adhesive Cleaner, P/N 08984, or equivalent.
8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use
88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry.
Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging
the repair area may result in an air leak.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast
Aluminum Wheels > Page 1744
10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire
Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on
the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and
inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the
tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire
and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty
one tube of adhesive/sealant per wheel repair.
For vehicles repaired under warranty, use:
One leak repair per wheel.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON
Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON
TECHNICAL
Bulletin No.: 08-03-10-006C
Date: April 27, 2010
Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated,
Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat)
Models:
2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 08-03-10-006B (Section 03 - Suspension).
Condition
Some customers may comment on a tire that slowly loses air pressure over a period of days or
weeks.
Cause
Abrasive elements in the environment may intrude between the tire and wheel at the bead seat.
There is always some relative motion between the tire and wheel (when the vehicle is driven) and
this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear
continues, there may also be intrusion at the tire/wheel interface by corrosive media from the
environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may
appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be
visible until the tire is dismounted from the wheel.
Notice
This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in
an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please
refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum
Wheels (Repair with Adhesive Sealant)
Correction
In most cases, this type of air loss can be corrected by following the procedure below.
Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to
repair the wheel with the procedure below.
Notice
The repair is no longer advised or applicable for chromed aluminum wheels.
1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and
Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to
be around the bead seat of the wheel, dismount the tire to examine
the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat
Corrosion
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 1749
Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel
flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for
additional information on possible wheel porosity issues.
3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a
rough or uneven surface that is difficult for the tire to
maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel
that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion
4. If corrosion is found on the wheel bead seat, measure the affected area as shown below.
- For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of
repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
- For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area
of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the
corrosion and any flaking paint. You should
remove the corrosion back far enough until you reach material that is stable and firmly bonded to
the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges
that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired
surface.
Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be
visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not
visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend
to the visible surfaces on the FACE of the wheel, that wheel must be replaced.
Important Remove ONLY the material required to eliminate the corrosion from the bead seating
surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as
smooth and level as possible.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 1750
Acceptably Prepared (Cleaned-Up) Wheel Surface
6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially
available tire sealant such as Patch Brand Bead
Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will
permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this
sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat
7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel
Removal and Installation in SI.
Parts Information
Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at
www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 1751
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion
INFORMATION
Bulletin No.: 00-03-10-002F
Date: April 21, 2011
Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum
Wheels
Models:
2012 and Prior GM Cars and Trucks
Supercede: This bulletin is being revised to update model years, suggest additional restorative
products and add additional corrosion information. Please discard Corporate Bulletin Number
00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the
customer.
What is Chemical Staining of Chrome Wheels? Figure 1
Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an
example). These stains are frequently milky, black, or greenish in appearance. They result from
using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient
to clean wheels.
If the customer insists on using a wheel cleaner they should only use one that specifically states
that it is safe for chromed wheels and does not contain anything in the following list. (Dealers
should also survey any products they use during prep or normal cleaning of stock units for these
chemicals.)
- Ammonium Bifluoride (fluoride source for dissolution of chrome)
- Hydrofluoric Acid (directly dissolves chrome)
- Hydrochloric Acid (directly dissolves chrome)
- Sodium Dodecylbenzenesulfonic Acid
- Sulfamic Acid
- Phosphoric Acid
- Hydroxyacetic Acid
Notice
Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most
customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal.
Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the
paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car
warranty. Soap and water applied with a soft brush is usually all that is required to clean the
calipers.
Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean,
clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts,
lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to
the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the
damage around and under the wheel weight where the cleaner was incompletely flushed away.
Notice
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Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 1757
Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome
wheels (or any wheels).
If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be
avoided.
For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and
Instructions below.
Warranty of Stained Chrome Wheels
Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome
wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were
returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be
charged back to the dealership. To assist the customer, refer to Customer Assistance and
Instructions below.
Pitting or Spotted Appearance of Chrome Wheels Figure 2
A second type or staining or finish disturbance may result from road chemicals, such as calcium
chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to
Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be
uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels
should be washed with mild soap and water and thoroughly rinsed as soon as conveniently
possible.
Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can
also stain chrome wheels. The staining will look like small pitting. This staining will usually be on
the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward
direction while being splashed by the road chemical. If a vehicle must be operated under such
conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed
as soon as conveniently possible.
Warranty of Pitted or Spotted Chrome Wheels
Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time.
Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish
and may cause damage if the wheels are not kept clean.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean if they are operating the vehicle in an area that
applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior
approval by the District Manager - Customer Care and Service Process (DM-CCSP).
"Stardust" Corrosion of Chrome Wheels Figure 3
A third type of finish disturbance results from prolonged exposure to brake dust and resultant
penetration of brake dust through the chrome. As brakes are applied hot particles of brake material
are thrown off and tend to be forced through the leading edge of the wheel spoke windows by
airflow. These
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 1758
hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed
to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the
chrome leaving a pit or small blister in the chrome.
Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and
Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up
or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars
Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be
waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax
#M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake
dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may
be used. It will clean and shine the chrome and leave behind a wax coating that may help protect
the finish.
Warranty of Stardust Corroded Chrome Wheels
Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be
replaced one time.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust
build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care
and Service Process (DM-CCSP).
Customer Assistance and Instructions
GM has looked for ways customers may improve the appearance of wheels damaged by acidic
cleaners. The following product and procedure has been found to dramatically improve the
appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the
following:
Notice
THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN
EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE
APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL
REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED
INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER,
EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS
EXACTLY.
1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce
wheel staining. Flood all areas of the wheel with water
to rinse.
2. Dry the wheels completely.
Notice Begin with a small section of the wheel and with light pressure buff off polish and examine
results. ONLY apply and rub with sufficient force and time to remove enough staining that you are
satisfied with the results. Some wheels may be stained to the extent that you may only achieve a
50% improvement while others may be able to be restored to the original lustre. IN ALL CASES,
only apply until the results are satisfactory.
3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the
polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the
towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If
continued applications fail to improve the appearance
further discontinue use.
This procedure will improve the appearance of the wheels and may, with repeated applications,
restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above
procedure may marginally improve the condition but will not restore the finish or remove the pitting.
In this type of staining the wheel finish has actually been removed in spots and no manner of
cleaning will restore the finish.
†*We believe this source and their products to be reliable. There may be additional manufacturers
of such products/materials. General Motors does not endorse, indicate any preference for or
assume any responsibility for the products or material from this firm or for any such items that may
be available from other sources.
Parts Information
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 1759
*This product is currently available from 3M. To obtain information for your local retail location
please call 3M at 1-888-364-3577.
**This product is currently available from Meguiars (Canada). To obtain information for your local
retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com.
^ This product is currently available from Tri-Peek International. To obtain information for your local
retail location please call Tri-Peek at
1-877-615-4272 or at www.tripeek.com.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum
Wheels
Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels
INFORMATION
Bulletin No.: 99-08-51-007E
Date: March 17, 2011
Subject: Refinishing Aluminum Wheels
Models:
2012 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add additional model years. Please discard Corporate
Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories).
This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not
endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic
refinishing of the wheel's coatings, using recommended procedures, is allowed.
Evaluating Damage
In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion,
scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be
sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the
wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been
refinished by an outside company must be returned to the same vehicle. The Dealer must record
the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to
Refinisher's Responsibility - Outside Company later in this bulletin.
Aluminum Wheel Refinishing Recommendations
- Chrome-plated aluminum wheels Re-plating these wheels is not recommended.
- Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the
clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be
performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later
in this bulletin.
- Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat
procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original
coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum
Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel.
- Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them.
In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is
possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel
should be resurfaced by using a sanding process rather than a machining process. This allows the
least amount of material to be removed.
Important Do not use any re-machining process that removes aluminum. This could affect the
dimensions and function of the wheel.
Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will
better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM
recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle
SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using
any of the painting options, it is recommended that all four wheels be refinished in order to maintain
color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures
and product recommendations.
Refinisher's Responsibility - Outside Company
Important Some outside companies are offering wheel refinishing services. Such refinished wheels
will be permanently marked by the refinisher and are warranted by the refinisher. Any process that
re-machines or otherwise re-manufactures the wheel should not be used.
A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent.
Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is
allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to
assure that the same wheel is returned. A plastic media blast may be used for clean up of the
wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed.
Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed.
Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel
mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel
and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the
new vehicle warranty, whichever is
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum
Wheels > Page 1764
longer.
Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact
surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut
torque.
When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to
reduce the chance of future cosmetic damage.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions
Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions
INFORMATION
Bulletin No.: 06-03-10-010A
Date: June 09, 2010
Subject: Information on Proper Wheel Changing Procedures and Cautions
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab
9-7X 2005-2009 Saturn Vehicles
Attention:
Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel
Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and
reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel
installation. Always refer to SI for wheel lug nut torque specifications and complete jacking
instructions for safe wheel changing.
Supercede: This bulletin is being revised to include the 2011 model year and update the available
special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension).
Frequency of Wheel Changes - Marketplace Driven
Just a few years ago, the increasing longevity of tires along with greater resistance to punctures
had greatly reduced the number of times wheels were removed to basically required tire rotation
intervals. Today with the booming business in accessory wheels/special application tires (such as
winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more
than ever. With this increased activity, it opens up more of a chance for error on the part of the
technician. This bulletin will review a few of the common concerns and mistakes to make yourself
aware of.
Proper Servicing Starts With the Right Tools
The following tools have been made available to assist in proper wheel and tire removal and
installation.
- J 41013 Rotor Resurfacing Kit (or equivalent)
- J 42450-A Wheel Hub Resurfacing Kit (or equivalent)
Corroded Surfaces
One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle.
Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened
wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed
away from water splash. This action may result in clearance at the mating surface of the wheel and
an under-torqued condition.
Caution
Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or
brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting
surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is
moving, possibly resulting in a loss of control or personal injury.
Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If
corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding
pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating
surface.
The J 41013 (or equivalent) can be used to clean the following surfaces:
- The hub mounting surface
- The brake rotor mounting surface
- The wheel mounting surface
Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub.
Lubricants, Grease and Fluids
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 1769
Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in
removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to
installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper
readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY.
Notice
Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or
drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to
clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light
coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel
pilot hole to prevent wheel seizure to the axle or bearing hub.
Wheel Stud and Lug Nut Damage
Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse.
You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not
retain properly, yet give the impression of fully tightening. Always inspect and replace any
component suspected of damage.
Tip
Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged
BEFORE tightening the nut.
Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side
of the tire is pointing in the direction of forward rotation.
Wheel Nut Tightening and Torque
Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid
additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown
for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in
order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off
center resulting in vibration.
The Most Important Service You Provide
While the above information is well known, and wheel removal so common, technicians run the risk
of becoming complacent on this very important
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 1770
service operation. A simple distraction or time constraint that rushes the job may result in personal
injury if the greatest of care is not exercised. Make it a habit to double check your work and to
always side with caution when installing wheels.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Page 1771
Wheels: Description and Operation
Replacement Wheels Description
Replace the wheel if any of the following conditions exist:
* The wheel exhibits excessive runout.
* The wheel is bent.
* The wheel is cracked.
* The wheel is severely rusted.
* The wheel is severely corroded.
Note: Air leaks caused by porosity on aluminum wheels are repairable.
* The wheel leaks air.
Warning
If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install
only new GM original equipment parts. Installation of used parts or non-GM original equipment
parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of
vehicle control resulting in personal injury.
Caution: The use of non-GM original equipment wheels may cause:
* Damage to the wheel bearing, the wheel fasteners and the wheel
* Tire damage caused by the modified clearance to the adjacent vehicle components
* Adverse vehicle steering stability caused by the modified scrub radius
* Damage to the vehicle caused by the modified ground clearance
* Speedometer and odometer inaccuracy
Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of
the following conditions exist:
* The wheel has elongated bolt holes.
* The wheel/nuts, or bolts if applicable, loosen repeatedly.
Steel wheel identification is stamped into the wheel near the valve stem.
Aluminum wheel identification is cast into the inboard side of the wheel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair
> Aluminum Wheel Porosity Repair
Wheels: Service and Repair Aluminum Wheel Porosity Repair
Aluminum Wheel Porosity Repair
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and
Installation (See: Service and Repair). 3. Inflate the tire to the manufacturer specified pressure as
stated on the tire. 4. Submerge the tire/wheel into a water bath in order to locate the leak. 5.
Inscribe a mark on the wheel in order to indicate the leak areas. 6. Inscribe a mark on the tire at the
valve stem in order to indicate the orientation of the tire to the wheel. 7. Remove the tire from the
wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and
Replacement).
Important: Do not damage the exterior surface of the wheel.
8. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 9. Use
general purpose cleaner such as 3M(R), P/N 08984 or equivalent, to clean the leak area.
10. Apply 3 mm (0.12 in) thick layer of adhesive/sealant, GM P/N 1052366 or equivalent, to the
leak area. 11. Allow for the adhesive/sealant to dry. 12. Align the inscribed mark on the tire with the
valve stem on the wheel. 13. Install the tire to the wheel. Refer to Tire Dismounting and Mounting
(See: Tires/Service and Repair/Removal and Replacement). 14. Inflate the tire to the manufacturer
specified pressure as stated on the tire. 15. Submerge the tire/wheel into a water bath in order
ensure the leak is sealed. 16. Balance the tire and wheel. Refer to Tire and Wheel Assembly
Balancing - Off Vehicle (See: Testing and Inspection/Symptom Related
Diagnostic Procedures/Vibration Diagnosis and Correction/Repair Instructions/Tire and Wheel
Assembly Balancing - Off Vehicle).
17. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and
Repair). 18. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair
> Aluminum Wheel Porosity Repair > Page 1774
Wheels: Service and Repair Aluminum Wheel Refinishing
Aluminum Wheel Refinishing
Finish Damage Evaluation Procedure
Note: *
If the wheels are chrome-plated, do not re-plate or refinish the wheels.
* If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize
a refinisher that meets manufacturer guidelines.
1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car
wash facilities. 2. Inspect the wheels for the following conditions:
* Corrosion
* Scrapes
* Gouges
3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for
cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim
flange is bent, discard the wheel.
Refinishing Procedure
Warning
To avoid serious personal injury when applying any two part component paint system, follow the
specific precautions provided by the paint manufacturer. Failure to follow these precautions may
cause lung irritation and allergic respiratory reaction.
1. Remove the tire and wheel assembly from the vehicle. Refer to Tire and Wheel Removal and
Installation (See: Service and Repair). 2. Remove the balance weights from the wheel. 3. Remove
the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and
Repair/Removal and Replacement). 4. Use a suitable cleaner in order to remove the following
contaminants from the wheel:
* Lubricants
* Wax
* Dirt
Note: *
Do not re-machine the wheel.
* Do not use chemicals in order to strip the paint from the wheel.
5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a
machined aluminum finish, spin the wheel and use sand paper in order to restore the circular
machined appearance.
Note: The wheel mounting surface and the wheel nut contact surface must remain free of paint.
7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint
manufacturer's instructions for painting the wheel. 9. Unmask the wheel.
10. Install a new valve stem.
Note: Use new coated balance weights in order to balance the wheel.
11. Install the tire to the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and
Repair/Removal and Replacement). 12. Use a suitable cleaner in order to remove the following
contaminants from the wheel mounting surface:
* Corrosion
* Overspray
* Dirt
13. Install the tire and wheel assembly to the vehicle. Refer to Tire and Wheel Removal and
Installation (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection
Wheel Bearing: Testing and Inspection
Wheel Bearings Diagnosis
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection > Page 1778
Wheel Bearing: Service and Repair
Front Wheel Bearing and Hub Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction
Control/Service Precautions/Technician Safety Information/Brake Dust Warning ).
Warning: Refer to ABS Component Handling Warning (See: Brakes and Traction Control/Service
Precautions/Technician Safety Information/ABS Component Handling Warning).
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and
Repair). 2. Remove the front brake caliper. Refer to Brake Caliper Replacement (See: Brakes and
Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Brake Caliper Replacement).
3. Remove the speed sensor electrical connector and the mounting bracket. Refer to Front Wheel
Speed Sensor Replacement (See: Brakes and
Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and
Repair/Front Wheel Speed Sensor Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection > Page 1779
4. To ensure the ease of removal, bundle speed sensor wiring harness so not to have it entangled
in any of the suspension components.
Note: The following service procedure applies to those vehicles that are equipped with 4 wheel
drive ONLY.
5. Remove the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Steering
and Suspension/Steering/Front Steering
Knuckle/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection > Page 1780
6. Remove the mounting bolts for the wheel bearing/hub, brake rotor assembly.
7. Remove the wheel bearing/hub, brake rotor assembly from the steering knuckle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection > Page 1781
Note: Perform the following service procedure with the brake rotor on a flat surface.
8. Remove the mounting bolt from the wheel bearing/hub, to the brake rotor.
Note: The splash shield will come off the steering knuckle when the wheel bearing/hub, brake rotor
is removed.
9. Remove the wheel bearing/hub from the brake rotor.
10. Clean the contact area between the wheel bearing/hub and the brake rotor.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection > Page 1782
1. Position the wheel bearing/hub assembly on the brake rotor. 2. Install the mounting bolts from
the wheel bearing/hub assembly to the brake rotor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: The following service procedure is to be performed on a flat surface and to ensure that the
brake rotor is securely attached to the hub assembly prior to the final torquing procedure. DO NOT
use air tools of any type for this procedure.
3. Tighten the bolts in crisscross pattern. Tighten the mounting bolts to 20 Nm (15 lb ft). 4. Install
the backing plate to the wheel bearing/hub, brake rotor assembly.
Note: The following service procedure applies to those vehicles that are equipped with 4 wheel
drive ONLY.
5. Install the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Steering
and Suspension/Steering/Front Steering
Knuckle/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection > Page 1783
6. Install the wheel bearing/hub, brake rotor assembly in the steering knuckle.
Note: When performing the following service procedure, DO NOT use air tools of any type to torque
the brake rotor to hub bolts.
7. Install the wheel bearing/hub, brake rotor mounting bolts and tighten to 125 Nm (92 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection > Page 1784
8. Install the brake caliper mounting bracket to the steering knuckle.
9. Install the mounting bolts for the brake caliper mounting bracket and tighten to 175 Nm (129 lb
ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection > Page 1785
10. Position a large screwdriver or pry bar in the cooling fins of the brake rotor and the brake
caliper mounting bracket.
Note: The following service procedure is to ensure that the brake rotor is seated properly on the
wheel bearing/hub assembly.
11. Tighten the mounting bolts for the brake rotor in sequence.
12. Using a torque wrench, tighten the mounting bolts to 110 Nm (81 lb ft). 13. Install the speed
sensor mounting bracket and re-connect the electrical connector. Refer to Front Wheel Speed
Sensor Replacement (See: Brakes
and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and
Repair/Front Wheel Speed Sensor Replacement).
14. Check for hub/rotor/bearing LRO specifications. Refer to Disc Brake Component Specifications
(See: Brakes and Traction Control/Disc Brake
System/Specifications/Disc Brake Component Specifications).
15. Install the brake caliper assembly. Refer to Brake Caliper Replacement (See: Brakes and
Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Brake Caliper Replacement).
16. Install the wheel speed sensor to the body. 17. Lower the vehicle. Refer to Lifting and Jacking
the Vehicle (See: Vehicle Lifting/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Drive Shaft Nut ....................................................................................................................................
.................................................... 260 Nm (191 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
Wheel Nuts...........................................................................................................................................
.......................................................140 Nm (103 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information >
Specifications > Page 1793
Wheel Fastener: Description and Operation
Metric Wheel Nuts and Bolts Description
Metric wheel/nuts and bolts are identified in the following way:
* The wheel/nut has the word Metric stamped on the face.
* The letter M is stamped on the end of the wheel bolt.
The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x
1.5.
* M = Metric
* 12 = Diameter in millimeters
* 1.5 = Millimeters gap per thread
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service
and Repair > Front Suspension
Wheel Fastener: Service and Repair Front Suspension
Wheel Stud Replacement
Tools Required
J 43631 Ball Joint Remover
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and
Installation (See: Service and Repair). 3. Remove the brake rotor. Refer to Brake Rotor
Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and
Repair/Removal and Replacement/Brake Rotor Replacement).
4. Remove the wheel stud from the hub flange using the J 43631 . 5. Remove the wheel stud from
the hub flange.
Installation Procedure
1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the
new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub
flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the
wheel nut. 6. Remove the washers.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service
and Repair > Front Suspension > Page 1796
7. Install the brake rotor. Refer to Brake Rotor Replacement (See: Brakes and Traction
Control/Disc Brake System/Brake Rotor/Disc/Service and
Repair/Removal and Replacement/Brake Rotor Replacement).
8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and
Repair). 9. Remove the safety stands.
10. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service
and Repair > Front Suspension > Page 1797
Wheel Fastener: Service and Repair Rear Suspension
Wheel Stud Replacement
Tools Required
J 43631 Ball Joint Separator
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the rear brake drum. Refer to Brake Drum Replacement
(See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service
and Repair/Removal and Replacement).
3. Using the J 43631 , remove the wheel stud.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service
and Repair > Front Suspension > Page 1798
1. Position the wheel stud in the axle flange. 2. Install the 4 washers and the lug nut to the stud. 3.
Tighten the lug nut until the stud fully seats. 4. Remove the lug nut and the washers.
5. Install the rear brake drum. Refer to Brake Drum Replacement (See: Brakes and Traction
Control/Drum Brake System/Brake Drum/Service and
Repair/Removal and Replacement).
6. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair
Vehicle Lifting: Service and Repair
Lifting and Jacking the Vehicle
Danger: To avoid any vehicle damage, serious personal injury or death when major components
are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack
stands at the opposite end from which the components are being removed and strap the vehicle to
the hoist.
Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands
to support the vehicle when lifting the vehicle with a jack.
Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
Vehicle Lifting
* Ensure that the lifting equipment meets weight requirements and is in good working order. Always
follow the lift manufacturer's instructions.
* You may lift and support the front of the vehicle at the front suspension near the wheel
assemblies. Ensure that the arms of the front cradle are extended as close to the steering knuckle
as possible.
* Ensure that the vehicle is centered on the hoist before attempting to lift.
* When using a suspension-contact hoist, ensure that the rear cradle has adequate clearance for
the rear stabilizer bar.
* When lifting or jacking a vehicle, be certain that the lift pads do not contact the exhaust system,
brake pipes, cables, HVAC lines, wiring harnesses, fuel lines, or underbody. Such contact may
result in damage or unsatisfactory vehicle performance.
* When using a frame-contact hoist, only place the pads on flat surfaces. Do not place pads within
50 mm (2 in) of any radius.
* Before lifting the vehicle, verify that the vehicle loads are secure and equally distributed.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 1802
* When major components are removed from the vehicle when supported on a hoist, support the
vehicle with jack stands at the opposite end from which the components are being removed and
secure the vehicle frame to the hoist pads nearest the component to be removed.
Vehicle Jacking
* Park the vehicle on a clean, hard, level surface before jacking the vehicle.
* Any time you lift the vehicle on one end, chock the wheels at the opposite end.
* Use jack stands in order to provide support.
* When supporting the vehicle using jack stands, place the jack stands under the side rails or the
axle.
* When lifting under the rear differential, do not allow the jack pad to contact the rear stabilizer bar
or mounting hardware.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable
Valve Timing Solenoid > Component Information > Diagrams
Variable Valve Timing Solenoid: Diagrams
Component Connector End Views
Camshaft Position (CMP) Actuator Solenoid Valve
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
COMPRESSION CHECK
If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the
combustion chamber through the spark plug hole. Measure the compression again and record the
reading. The minimum compression in any 1 cylinder should not be less than 70 percent of the
highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest
pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other
cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 1812
Compression Check: Testing and Inspection
Engine Compression Test
1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable
the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6.
Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression
gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the
compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject
approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark
plug
hole. Measure the compression again and record the reading.
10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690 kPa
(100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest
allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x
70% = 105).
* Normal - Compression builds up quickly and evenly to the specified compression for each
cylinder.
* Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the
following strokes, but does not reach normal. Compression improves considerably when you add
oil.
* Valves Leaking - Compression is low on the first stroke. Compression usually does not build up
on the following strokes. Compression does not improve much when you add oil.
* If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders
does not increase the compression, the cause may be a head gasket leaking between the
cylinders.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
CAMSHAFT GEAR/SPROCKET
Camshaft Sprocket Bolt First Pass.......................................................................................................
................................................................................................75 Nm (55 lb ft) Final Pass...................
..............................................................................................................................................................
..............................50 degrees
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair
Camshaft: Service and Repair
Camshaft Replacement
Special Tools
* EN 46330 Timing Belt Tensioner Retaining Pin
* EN 46330 Angle Meter
Removal Procedure
1. Remove the condenser. Refer to Air Conditioning Condenser Replacement (See: Heating and
Air Conditioning/Condenser HVAC/Service and
Repair).
2. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Timing
Components/Timing Cover/Service and Repair). 3. Remove all of the valve lifters. Refer to Valve
Lifter Replacement (See: Lifter / Lash Adjuster/Service and Repair).
4. Remove the camshaft sensor bolt and sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair > Page 1820
5. Rotate the crankshaft until the timing marks on the crankshaft and camshaft sprockets are
aligned.
6. Remove the camshaft sprocket bolt (206).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair > Page 1821
7. Remove the bolts (231) and timing chain tensioner (232). 8. Remove the camshaft sprocket and
reposition the timing chain.
9. Remove the camshaft retainer bolts (204) and retainer (203).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair > Page 1822
Caution: All camshaft journals are the same diameter, so care must be used in removing or
installing the camshaft to avoid damage to the camshaft bearings.
10. Install a bolt into the camshaft. 11. Using the bolt as a handle, carefully rotate and pull the
camshaft out of the engine block. 12. Clean and inspect the camshaft and bearings. Refer to
Camshaft and Bearings Cleaning and Inspection ().
Installation Procedure
Note: If camshaft replacement is required, the valve lifters must also be replaced.
1. Lubricate the camshaft journals and the bearings with clean engine oil.
Caution: All camshaft journals are the same diameter, so care must be used in removing or
installing the camshaft to avoid damage to the camshaft bearings.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair > Page 1823
2. Using the bolt as a handle, carefully install the camshaft into the engine block. 3. Remove the
bolt from the front of the camshaft.
Note: Install the retainer with the sealing gasket facing the engine block.
The gasket surface on the engine block should be clean and free of dirt and/or debris.
4. Install the camshaft retainer (203) and bolts (204).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Tighten the camshaft retainer bolts.
* Tighten the first design hex head bolts (3) to 25 Nm (18 lb ft).
* Tighten the second design TORX(R) head bolts (4) to 15 Nm (11 lb ft).
6. Compress the timing chain tensioner guide and install the EN 46330 .
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair > Page 1824
7. Install the timing chain tensioner (232) and bolts (231).
Tighten the timing chain tensioner bolts to 25 Nm (18 lb ft).
Note: *
Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole.
* The sprocket teeth and timing chain must mesh.
* The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. Locate
the camshaft sprocket alignment mark (1) in the 6 o'clock position and the crankshaft sprocket (2)
should be located in the 12 o'clock position.
8. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair > Page 1825
9. Install the camshaft sprocket (205) and the timing chain (208).
10. Install a NEW camshaft sprocket bolt (206).
11. Tighten the camshaft sprocket bolt.
1. Tighten the camshaft sprocket bolt a first pass to 75 Nm (55 lb ft). 2. Tighten the camshaft
sprocket bolt a final pass, an additional 50 degrees using the J 45059 .
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair > Page 1826
12. Remove the EN 46330 .
13. Inspect the camshaft sensor O-ring seal. If the O-ring seal is not cut or damaged, it may be
reused. 14. Lubricate the O-ring seal with clean engine oil. 15. Install the camshaft sensor and bolt.
Tighten the bolt to 25 Nm (18 lb ft).
16. Install the valve lifters. Refer to Valve Lifter Replacement (See: Lifter / Lash Adjuster/Service
and Repair). 17. Install the engine front cover. Refer to Engine Front Cover Replacement (See:
Timing Components/Timing Cover/Service and Repair). 18. Install the condenser. Refer to Air
Conditioning Condenser Replacement (See: Heating and Air Conditioning/Condenser
HVAC/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair
Lifter / Lash Adjuster: Service and Repair
Valve Lifter Replacement
Tools Required
J 3049-A Valve Lifter Remover
Removal Procedure
1. Remove the cylinder head and gasket. Refer to Cylinder Head Replacement - Left Side (See:
Cylinder Head Assembly/Service and Repair) or to
Cylinder Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair).
2. Remove the valve lifter. Refer to Valve Lifter Removal (See: Service and Repair/Overhaul). 3.
Clean and inspect the valve lifters. Refer to Valve Lifter and Guide Cleaning and Inspection (See:
Service and Repair/Overhaul).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Page 1830
1. Install the valve lifter. Refer to Valve Lifter Installation (See: Service and Repair/Overhaul).
2. Install the cylinder head and gasket. Refer to Cylinder Head Replacement - Left Side (See:
Cylinder Head Assembly/Service and Repair) or to
Cylinder Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod >
Component Information > Service and Repair
Push Rod: Service and Repair
Valve Rocker Arm and Push Rod Replacement
Removal Procedure
1. Remove the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See:
Cylinder Head Assembly/Valve Cover/Service
and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover
Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve
Rocker Arm Cover Replacement - Right Side).
Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank.
2. Remove the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up
and Engine Performance Checks/Spark
Plug/Service and Repair).
Note: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in
the same location from which they were removed.
3. Remove the rocker arm bolts. 4. Remove the rocker arms.
5. Remove the rocker arm pivot support.
6. Remove the pushrods. 7. Clean and inspect the rocker arms and pushrods, if required. Refer to
Valve Rocker Arm and Push Rod Cleaning and Inspection (See: Service
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod >
Component Information > Service and Repair > Page 1834
and Repair/Overhaul).
Installation Procedure
Note: When reusing the valve train components, always install the components to the original
location and position.
Valve lash is net build, no valve adjustment is required.
1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the
rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will
contact the rocker
arm.
3. Install the rocker arm pivot support.
Note: Make sure that the pushrods seat properly to the valve lifter sockets.
4. Install the pushrods.
Note: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten
the rocker arm bolts at this time.
5. Install the rocker arms and bolts.
Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank.
Cylinders 2, 4, 6 and 8 are the right bank.
6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the
compression stroke. In this position, the number one cylinder
rocker arms will be off lobe lift.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod >
Component Information > Service and Repair > Page 1835
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. With the engine in the number one firing position, tighten the following rocker arm bolts:
* Tighten cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 lb ft).
* Tighten cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 lb ft).
8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts:
* Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 lb ft).
* Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 lb ft).
10. Install the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up
and Engine Performance Checks/Spark Plug/Service
and Repair).
11. Install the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See:
Cylinder Head Assembly/Valve Cover/Service and
Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover
Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve
Rocker Arm Cover Replacement - Right Side).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Valve Rocker Arm and Push Rod Replacement
Removal Procedure
1. Remove the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See:
Cylinder Head Assembly/Valve Cover/Service
and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover
Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve
Rocker Arm Cover Replacement - Right Side).
Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank.
2. Remove the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up
and Engine Performance Checks/Spark
Plug/Service and Repair).
Note: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in
the same location from which they were removed.
3. Remove the rocker arm bolts. 4. Remove the rocker arms.
5. Remove the rocker arm pivot support.
6. Remove the pushrods. 7. Clean and inspect the rocker arms and pushrods, if required. Refer to
Valve Rocker Arm and Push Rod Cleaning and Inspection (See: Service
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Page 1839
and Repair/Overhaul).
Installation Procedure
Note: When reusing the valve train components, always install the components to the original
location and position.
Valve lash is net build, no valve adjustment is required.
1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the
rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will
contact the rocker
arm.
3. Install the rocker arm pivot support.
Note: Make sure that the pushrods seat properly to the valve lifter sockets.
4. Install the pushrods.
Note: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten
the rocker arm bolts at this time.
5. Install the rocker arms and bolts.
Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank.
Cylinders 2, 4, 6 and 8 are the right bank.
6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the
compression stroke. In this position, the number one cylinder
rocker arms will be off lobe lift.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Page 1840
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. With the engine in the number one firing position, tighten the following rocker arm bolts:
* Tighten cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 lb ft).
* Tighten cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 lb ft).
8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts:
* Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 lb ft).
* Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 lb ft).
10. Install the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up
and Engine Performance Checks/Spark Plug/Service
and Repair).
11. Install the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See:
Cylinder Head Assembly/Valve Cover/Service and
Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover
Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve
Rocker Arm Cover Replacement - Right Side).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod
Bearing > Component Information > Specifications
Connecting Rod Bearing: Specifications
CONNECTING ROD
Connecting Rod Bearing Clearance Production...................................................................................
...................................................................................0.023-0.065 mm (0.0009-0.0025 in) Service.....
..............................................................................................................................................................
..........0.023-0.076 mm (0.0009-0.003 in)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod,
Engine > Component Information > Specifications
Connecting Rod: Specifications
CONNECTING ROD
Connecting Rod Bore Diameter - Bearing
End................................................................................................................56.505-56.525 mm
(2.224-2.225 in)
Connecting Rod Bore Out-of-Round - Bearing End Production...........................................................
.........................................................................................................0.004-0.008 mm
(0.00015-0.0003 in) Service.................................................................................................................
........................................................0.004-0.008 mm (0.00015-0.0003 in)
Connecting Rod Length - Center to
Center..........................................................................................................................144.75-144.81
mm (5.69-5.70 in)
Connecting Rod Bolts First Pass..........................................................................................................
.............................................................................................20 Nm (15 lb ft) Final Pass......................
..............................................................................................................................................................
...........................85 degrees
Connecting Rod Side Clearance..........................................................................................................
..................................0.11-0.51 mm (0.00433-0.02 in)
Connecting Rod Journal Diameter Production.....................................................................................
.............................................................................53.318-53.338 mm (2.0991-2.0999 in) Service.......
..............................................................................................................................................................
...........................53.308 mm (2.0987 in) Connecting Rod Journal Out-of-Round Production..............
..............................................................................................................................................................
................0.005 mm (0.0002 in) Service..............................................................................................
......................................................................................................0.01 mm (0.0004 in) Connecting
Rod Journal Taper - Maximum for 1/2 of Journal Length Production...................................................
.........................................................................................................................................0.005 mm
(0.0002 in) Service...............................................................................................................................
...................................................................0.02 mm (0.00078 in)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main
Bearing > Component Information > Specifications
Crankshaft Main Bearing: Specifications
CRANKSHAFT
CRANKSHAFT MAIN BEARING CLEARANCE
Crankshaft Main Bearing Clearance Production..................................................................................
......................................................................................0.02-0.052 mm (0.0008-0.0021 in) Service....
..............................................................................................................................................................
...........0.02-0.065 mm (0.0008-0.0025 in) MAIN BEARING CAP
Crankshaft Bearing Cap M8 Bolts........................................................................................................
..........................................................25 Nm (18 lb ft)
Crankshaft Bearing Cap M10 Bolts First Pass in Sequence................................................................
...................................................................................................................20 Nm (15 lb ft) Final Pass
in Sequence..........................................................................................................................................
.................................................80 degrees
Crankshaft Main Bearing Bore Diameter..............................................................................................
.............................69.871-69.889 mm (2.75-2.751 in) Crankshaft Main Bearing Bore Out-of-Round..
......................................................................................................................................0.006 mm
(0.0002 in)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal
Retainer > Component Information > Service and Repair
Crankshaft Seal Retainer: Service and Repair
Crankshaft Rear Oil Seal Housing Replacement
Special Tools
* J-41476 - Front and Rear Cover Alignment Tool
* J-41479-2A - Crankshaft Rear Oil Seal Installation Guide
Removal Procedure
1. Remove the automatic transmission flexplate. Refer to Automatic Transmission Flex Plate
Replacement (See: Transmission and Drivetrain/Flex
Plate/Service and Repair/Automatic Transmission Flex Plate Replacement).
2. Remove the oil pan-to-rear oil seal housing bolts (1).
3. Remove the rear oil seal housing bolts (1). 4. Remove the rear oil seal housing (2) and gasket
(3). Discard the gasket. 5. Remove and discard the rear oil seal (4).
Installation Procedure
Note: *
Do not reuse the crankshaft oil seal or rear cover gasket.
* Do not apply any type of sealant to the rear cover gasket, unless specified.
* The special tool in this procedure is used to properly center the crankshaft rear oil seal.
* All gasket surfaces should be free of oil or other foreign material during assembly.
* The crankshaft rear oil seal MUST be centered in relation to the crankshaft.
* An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly
oil leaks.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal
Retainer > Component Information > Service and Repair > Page 1854
1. Apply a 5 mm (0.2 in) bead of sealant, 20 mm (0.8 in) to the 2 joints (a) at the rear of the
block/pan. Refer to Adhesives, Fluids, Lubricants, and
Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers).
2. Inspect the rear oil gallery plug for proper installation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal
Retainer > Component Information > Service and Repair > Page 1855
Installation Procedure - Cover with Seal
1. Install the J-41479-2A - guide cone and bolts onto the rear of the crankshaft.
2. Install the NEW rear housing gasket (1), rear housing with seal (2), rear housing-to-engine bolts
(3) and oil pan-to-rear housing bolts (4).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the rear housing-to-engine bolts (3) until snug. Do not overtighten. 4. Tighten the oil
pan-to-rear housing bolts (4) to 12 Nm (106 lb in). 5. Tighten the rear housing-to-engine bolts (3) to
30 Nm (22 lb ft). 6. Remove the J-41479-2A - guide. 7. Install the automatic transmission flexplate.
Refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex
Plate/Service and Repair/Automatic Transmission Flex Plate Replacement).
Installation Procedure - Cover without Seal
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal
Retainer > Component Information > Service and Repair > Page 1856
1. Position a NEW rear oil seal housing gasket (3) and the housing (2) to the engine. 2. Install the
rear oil seal housing bolts (1) until snug. Do not overtighten. 3. Rotate the crankshaft until 2
opposing flywheel bolts holes are parallel to the oil pan surface.
Note: The tapered legs of the alignment tool must enter the rear cover oil seal bore.
4. Install the J-41476 - tool and bolts onto the rear of the crankshaft. 5. Tighten the J-41476 - tool
bolts until snug. Do not overtighten.
6. Install the oil pan-to-rear oil seal housing bolts (1).
1. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 lb in). 2. Tighten the rear oil seal
housing-to-engine bolts to 30 Nm (22 lb ft).
7. Remove the J-41476 - tool.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal
Retainer > Component Information > Service and Repair > Page 1857
8. Install a NEW crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Replacement (See:
Seals and Gaskets/Crankshaft Main Bearing
Seal/Service and Repair).
9. Install the automatic transmission flexplate. Refer to Automatic Transmission Flex Plate
Replacement (See: Transmission and Drivetrain/Flex
Plate/Service and Repair/Automatic Transmission Flex Plate Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications
CRANKSHAFT
Crankshaft Main Journal Diameter Production.....................................................................................
.................................................................................64.992-65.008 mm (2.558-2.559 in) Service.......
..............................................................................................................................................................
.............................64.992 mm (2.558 in) Crankshaft Main Journal Out-of-Round Production.............
..............................................................................................................................................................
.............0.003 mm (0.000118 in) Service.............................................................................................
.....................................................................................................0.008 mm (0.0003 in) Crankshaft
Main Journal Taper Production............................................................................................................
..................................................................................0.01 mm (0.0004 in) Service..............................
..............................................................................................................................................................
......0.02 mm (0.00078 in) Crankshaft Rear Flange Runout..................................................................
................................................................................................0.05 mm (0.002 in) Crankshaft
Reluctor Ring Runout - Measured 1.0 mm (0.04 in) Below Tooth
Diameter.............................................................................0.7 mm (0.028 in) Crankshaft Thrust
Surface Production...............................................................................................................................
.........................................26.14-26.22 mm (1.029-1.0315 in) Service.................................................
.................................................................................................................................................26.22
mm (1.0315 in) Crankshaft Thrust Surface Runout..............................................................................
.............................................................................0.025 mm (0.001 in) Crankshaft End Play...............
...............................................................................................................................................0.04-0.2
mm (0.0015-0.0078 in)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair > Coolant Heater Replacement
Engine Block Heater: Service and Repair Coolant Heater Replacement
Coolant Heater Replacement (With LH8) (5.3L)
Removal Procedure
1. Drain the cooling system/engine block. Refer to Cooling System Draining and Filling (Static Fill)
(See: Cooling System/Service and Repair
)Cooling System Draining and Filling (Vac N Fill) (See: Cooling System/Service and Repair).
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 3. Disconnect the coolant heater cord electrical
connector.
Note: Do not score the surface of the engine block hole when removing the coolant heater.
4. Remove the coolant heater from the engine block. 5. Remove any burrs, sealer, or other rough
spots.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair > Coolant Heater Replacement > Page 1865
Installation Procedure
1. If reusing the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N
10953480), or equivalent to the threads.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the coolant heater to the engine block. Tighten the coolant heater to 50 Nm (37 lb ft).
3. Connect the coolant heater cord electrical connector. 4. Lower the vehicle. 5. Fill the cooling
system/engine block. Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling
System/Service and Repair
)Cooling System Draining and Filling (Vac N Fill) (See: Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair > Coolant Heater Replacement > Page 1866
Engine Block Heater: Service and Repair Coolant Heater Cord Replacement
Coolant Heater Cord Replacement (With LH8) (5.3L)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the coolant heater cord electrical
connector. 3. Remove the coolant heater cord clip from the engine harness channel. 4. Remove
the coolant heater cord clip from the power steering gear outlet hose. 5. Lower the vehicle. 6.
Remove the coolant heater cord bolt from the frame. 7. Remove the coolant heater cord from the
vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair > Coolant Heater Replacement > Page 1867
1. Install the coolant heater cord to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Position the coolant heater cord clip to the frame and install the coolant heater cord bolt. Tighten
the bolt to 8 Nm (71 lb in). 3. Raise the vehicle. 4. Install the coolant heater cord clip to the power
steering gear outlet hose. 5. Install the coolant heater cord clip to the engine harness channel. 6.
Connect the coolant heater cord electrical connector. 7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
CRANKSHAFT PULLEY
Crankshaft Balancer Bolt First Pass.....................................................................................................
..............................................................................................150 Nm (111 lb ft) Second Pass.............
..............................................................................................................................................................
................. Loosen 360 degrees Third Pass.........................................................................................
............................................................................................................50 Nm (37 lb ft) Final Pass.......
..............................................................................................................................................................
........................................230 degrees
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1871
Harmonic Balancer - Crankshaft Pulley: Service and Repair
Crankshaft Balancer Replacement
Special Tools
* J 41478 Crankshaft Front Oil Seal Installer
* J 41665 Crankshaft Balancer and Sprocket Installer
* J 41816-A Crankshaft Balancer Remover
* J 41816-2 Crankshaft End Protector
* J 42386-A Flywheel Holding Tool
* J 45059 Angle Meter
Removal Procedure
1. Remove the air conditioning (A/C) drive belt. Refer to Air Conditioning Compressor Belt
Replacement (See: Drive Belts, Mounts, Brackets and
Accessories/Drive Belt/Service and Repair/Air Conditioning Compressor Belt Replacement).
2. Remove the cooling fan and shroud. Refer to Engine Coolant Fan Shroud Replacement (LLV,
LLR) (See: Cooling System/Fan Shroud/Service
and Repair)Engine Coolant Fan Shroud Replacement (LH8) (See: Cooling System/Fan
Shroud/Service and Repair).
3. Remove the starter motor. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and
Charging/Starting System/Starter Motor/Service
and Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: Ensure that the teeth of the J 42386-A mesh with the teeth of the engine flywheel.
4. Install the J 42386-A (1) and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt
for proper tool operation.
Tighten the J 42386-A bolts to 50 Nm (37 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1872
5. Remove the crankshaft balancer bolt (139). Do not discard the crankshaft balancer bolt at this
time. The old balancer bolt will be used during the
balancer installation procedure.
6. Install the J 41816 (1) and J 41816-2 (2) to the crankshaft balancer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1873
Note: The crankshaft balancer is balanced as an individual component. It is not necessary to mark
the balancer prior to removal.
7. Use the J 41816 and the J 41816-2 to remove the crankshaft balancer (138). 8. Remove the J
41816 and the J 41816-2 from the crankshaft balancer.
Installation Procedure
Note:
* The crankshaft balancer installation and bolt tightening involves a four stage tightening process.
The first pass ensures that the balancer is installed completely onto the crankshaft. The second,
third, and fourth passes tighten the NEW bolt to the proper torque.
* The used crankshaft balancer bolt will be used ONLY during the first pass of the balancer
installation procedure. Install a NEW bolt and tighten as described in the second, third and fourth
passes of the balancer bolt tightening procedure.
Note: The balancer should be positioned onto the end of the crankshaft as straight as possible prior
to tool installation.
1. Position the crankshaft balancer (138) onto the end of the crankshaft.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1874
2. Install the J 41665 and the threaded rod from the J 41478 to crankshaft balancer and install the
balancer.
1. Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into
the front of the balancer. 2. Use a wrench and hold the hex end of the threaded rod. 3. Use a
second wrench and rotate the installation tool nut clockwise until the balancer is started onto the
crankshaft. 4. Remove the tool and reverse the installation tool. Position the larger end of the
installer against the front of the balancer.
5. Use a wrench and hold the hex end of the threaded rod. 6. Use a second wrench and rotate the
installation tool nut clockwise until the balancer is installed onto the crankshaft. 7. Remove the J
41665 and the threaded rod.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the USED crankshaft balancer bolt (139).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1875
Tighten the USED bolt to 330 Nm (240 lb ft).
4. Remove the USED crankshaft balancer bolt.
Note: The nose of the crankshaft should be recessed 2.4-4.48 mm (0.094-0.176 in) into the
balancer bore.
5. Measure for a correctly installed balancer. If the balancer is not installed to the proper
dimension, install the J 41665 and repeat the installation
procedure.
6. Install the NEW crankshaft balancer bolt (139).
1. Tighten the bolt a first pass to 50 Nm (37 lb ft). 2. Tighten the bolt a final pass to 140 degrees
using J 45059 .
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1876
7. Remove the J 42386-A (1) and bolts. 8. Install the starter motor. Refer to Starter Motor
Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and
Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
9. Install the cooling fan and shroud. Refer to Engine Coolant Fan Shroud Replacement (LLV, LLR)
(See: Cooling System/Fan Shroud/Service and
Repair)Engine Coolant Fan Shroud Replacement (LH8) (See: Cooling System/Fan Shroud/Service
and Repair).
10. Install the A/C drive belt. Refer to Air Conditioning Compressor Belt Replacement (See: Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Air Conditioning Compressor Belt Replacement).
11. Perform the crankshaft position (CKP) system variation learn procedure. Refer to Crankshaft
Position System Variation Learn (See: Powertrain
Management/Computers and Control Systems/Crankshaft Position Sensor/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
PISTON CLEARANCE
Piston-to-Bore Clearance Production...................................................................................................
....................................................-0.036 to +0.016 mm (-0.0014 to +0.0006 in) Service Limit with
Skirt Coating Worn
Off..........................................................................................................................................0.071
mm (0.0028 in)
PISTON DIAMETER
Piston Diameter - Measured Over Skirt
Coating..........................................................................................................96.002-96.036 mm
(3.7796-3.7809 in)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
PISTON RING END GAP
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore Production...................
...........................................................................................................................................................0.
23-0.44 mm (0.009-0.017 in) Service...................................................................................................
................................................................................0.23-0.5 mm (0.009-0.0196 in) Piston Ring End
Gap - Second Compression Ring - Measured in Cylinder Bore Production.........................................
.......................................................................................................................................0.44-0.7 mm
(0.017-0.027 in) Service.......................................................................................................................
............................................................0.44-0.76 mm (0.0173-0.03 in) Piston Ring End Gap - Oil
Control Ring - Measured in Cylinder Bore Production..........................................................................
....................................................................................................0.18-0.75 mm (0.007-0.029 in) Servi
ce..........................................................................................................................................................
.........................0.18-0.81 mm (0.007-0.032 in)
PISTON RING TO GROOVE CLEARANCE Piston Ring-to-Groove Clearance - First Compression
Ring Production....................................................................................................................................
................................0.04-0.085 mm (0.00157-0.00335 in) Service......................................................
...................................................................................................................0.04-0.085 mm
(0.00157-0.00335 in) Piston Ring-to-Groove Clearance - Second Compression Ring Production......
..............................................................................................................................................................
..0.04-0.078 mm (0.00157-0.0031 in) Service......................................................................................
.....................................................................................0.04-0.078 mm (0.00157-0.0031 in) Piston
Ring-to-Groove Clearance - Oil Control Ring Production.....................................................................
.....................................................................................................0.012-0.2 mm (0.0005-0.0078 in) S
ervice....................................................................................................................................................
...........................0.012-0.2 mm (0.0005-0.0078 in)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning
(See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID).
2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine
cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail
service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten
the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1888
Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel
Pressure Relief (With CH 48027))Fuel Pressure
Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)).
2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or
diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's
directions.
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1889
1. Relieve the fuel system pressure, if required. Perform the following steps:
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from
the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the
fuel rail service port cap. 6. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1890
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH-48027)
Special Tools
CH-48027 - Digital Pressure Gage
Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery
and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID).
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1891
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT
necessary to proceed with the following steps.
12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4)
from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and
place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the
engine cover, if required. 17. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly
> Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Valve Rocker Arm and Push Rod Replacement
Removal Procedure
1. Remove the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See:
Valve Cover/Service and Repair/Valve Rocker
Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See:
Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side).
Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank.
2. Remove the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up
and Engine Performance Checks/Spark
Plug/Service and Repair).
Note: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in
the same location from which they were removed.
3. Remove the rocker arm bolts. 4. Remove the rocker arms.
5. Remove the rocker arm pivot support.
6. Remove the pushrods. 7. Clean and inspect the rocker arms and pushrods, if required. Refer to
Valve Rocker Arm and Push Rod Cleaning and Inspection (See: Service
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly
> Component Information > Service and Repair > Page 1895
and Repair/Overhaul).
Installation Procedure
Note: When reusing the valve train components, always install the components to the original
location and position.
Valve lash is net build, no valve adjustment is required.
1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the
rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will
contact the rocker
arm.
3. Install the rocker arm pivot support.
Note: Make sure that the pushrods seat properly to the valve lifter sockets.
4. Install the pushrods.
Note: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten
the rocker arm bolts at this time.
5. Install the rocker arms and bolts.
Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank.
Cylinders 2, 4, 6 and 8 are the right bank.
6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the
compression stroke. In this position, the number one cylinder
rocker arms will be off lobe lift.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly
> Component Information > Service and Repair > Page 1896
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. With the engine in the number one firing position, tighten the following rocker arm bolts:
* Tighten cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 lb ft).
* Tighten cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 lb ft).
8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts:
* Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 lb ft).
* Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 lb ft).
10. Install the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up
and Engine Performance Checks/Spark Plug/Service
and Repair).
11. Install the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See:
Valve Cover/Service and Repair/Valve Rocker
Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See:
Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side
Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Left Side
Valve Rocker Arm Cover Replacement - Left Side
Removal Procedure
1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement
(See: Intake Manifold/Service and Repair). 2. Remove the connector position assurance (CPA)
retainer (2). 3. Disconnect the engine harness electrical connector (1) from the ignition coil wire
harness. 4. Remove the engine harness clip (4) from the ignition coil bracket stud. 5. Reposition
the engine harness, as necessary.
6. Remove the spark plug wires (724) from the ignition coils.
* Twist each plug wire 1/2 turn.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1901
* Pull only on the boot in order to remove the wire from the ignition coil.
7. Remove the ignition coil bracket studs (720). 8. Remove the ignition coil bracket (719).
9. Remove the positive crankcase ventilation (PCV) hose.
10. Loosen the valve rocker arm cover bolts. 11. Remove the valve rocker arm cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1902
12. Remove and discard the old gasket (1).
Installation Procedure
Note:
* All gasket surfaces should be free of oil an/or other foreign material during assembly.
* DO NOT reuse the valve rocker arm cover gasket.
* If the PCV valve grommet has been removed from the rocker cover, install a NEW grommet
during assembly.
1. Install a NEW rocker cover gasket (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1903
2. Install the valve rocker arm cover.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the rocker arm cover bolts.
Tighten the bolts to 12 Nm (106 lb in).
4. Install the PCV hose.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1904
5. Apply threadlock to the threads of the ignition coil bracket studs. Refer to Adhesives, Fluids,
Lubricants, and Sealers (See:
Specifications/Adhesives, Fluids, Lubricants, and Sealers).
6. Position the ignition coil bracket (719) onto the rocker cover. 7. Install the ignition coil bracket
studs (720).
Tighten the studs to 12 Nm (106 lb in).
8. Install the spark plug wires (724) to the ignition coils.
9. Position the engine harness, as necessary.
10. Install the engine harness clip (4) to the ignition coil bracket stud. 11. Connect the engine
harness electrical connector (1) to the ignition coil wire harness. 12. Install the CPA retainer (2). 13.
Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Intake Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1905
Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Right Side
Valve Rocker Arm Cover Replacement - Right Side
Removal Procedure
1. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Intake Manifold/Service and
Repair).
2. Remove the connector position assurance (CPA) lock. 3. Disconnect the main electrical
connector (1) to the ignition coil wire harness. 4. Remove the harness clips. 5. Reposition the
engine harness, if necessary. 6. Remove the spark plug wires from the ignition coils.
* Twist each plug wire 1/2 turn.
* Pull only on the boot in order to remove the wire from the ignition coil.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1906
7. Remove the heater hose bracket bolt (1) from the front of the right cylinder head.
8. If necessary, remove the ignition coil bracket studs from the rocker arm cover. 9. If necessary,
remove the ignition coils and bracket from the rocker cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1907
10. Remove the vent hose (2) from the valve rocker arm cover (1).
11. Remove the valve rocker arm cover bolts. 12. Remove the valve rocker arm cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1908
13. Remove the gasket (1) from the rocker cover. 14. Discard the OLD gasket.
15. Remove the oil fill cap from the oil fill tube. 16. Remove the oil fill tube from the rocker cover, if
required. 17. Discard the oil fill tube.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1909
Note: *
All gasket surfaces should be free of oil or other foreign material during assembly.
* DO NOT reuse the valve rocker arm cover gasket.
* The valve rocker arm cover bolt grommets may be reused.
* If the oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during
assembly.
1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil. 2. Insert the NEW oil fill
tube into the rocker arm cover.
Rotate the tube clockwise until locked in the proper position.
3. Install the oil fill cap into the tube.
Rotate the cap clockwise until locked in the proper position.
4. Install a NEW rocker cover gasket (1) into the valve rocker arm cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1910
5. Install the valve rocker arm cover onto the cylinder head. 6. Install new rocker arm cover
grommets, if necessary.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. Install the rocker arm cover bolts and grommets and tighten the bolts to 12 Nm (106 lb in).
8. Install the vent hose (2) to the valve rocker arm cover (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1911
9. Apply threadlock to the threads of the bracket bolts. Refer to Adhesives, Fluids, Lubricants, and
Sealers (See: Specifications/Adhesives, Fluids,
Lubricants, and Sealers) for the correct part number.
10. If necessary, install the ignition coils and bracket to the rocker arm cover. 11. If necessary,
install the ignition coil bracket studs to the rocker cover.
Tighten the studs to 12 Nm (106 lb in).
12. Install the heater hose bracket bolt (1) to the front of the right cylinder head.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1912
13. Install the spark plug wires to the ignition coils. 14. Position the engine harness, if necessary.
15. Install the harness clips. 16. Connect the main electrical connector (1) feeding the ignition coils.
17. Install the CPA lock. 18. Install the upper intake manifold sight shield. Refer to Upper Intake
Manifold Sight Shield Replacement (See: Intake Manifold/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions
Valve Spring: Service Precautions
Valve Springs Can Be Tightly Compressed Warning
Warning
Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal
injury could result.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions > Page 1916
Valve Spring: Service and Repair
Valve Stem Oil Seal and Valve Spring Replacement
Special Tools
* J 22794 Spark Plug Port Adapter
* J 38606 Valve Spring Compressor
Removal Procedure
1. Remove the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Rocker
Arm Assembly/Service and Repair). 2. Disconnect the spark plug wire at the spark plug.
* Twist each plug wire boot 1/2 turn.
* Pull only on the boot in order to remove the wire from the spark plug.
Note: Remove the spark plugs from the cylinder head with the engine at room temperature.
3. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the
spark plug. 5. Remove the spark plug.
6. Install the J 22794 into the spark plug hole. 7. Attach an air hose to the J 22794 . 8. Apply
compressed air to the J 22794 in order to hold the valves in place.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions > Page 1917
9. Use the J 38606 in order to compress the valve spring.
10. Remove the valve stem keys (225). 11. Carefully release the valve spring tension. 12. Remove
the J 38606 . 13. Remove the valve spring cap (224). 14. Remove the valve spring (223). 15.
Remove the valve stem oil seal (222). 16. Remove the valve (228).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions > Page 1918
1. Clean the cylinder head valve spring seat area. 2. Lubricate the valve guide and valve stem oil
seal with clean engine oil. 3. Install the valves (228) into the proper port. 4. Install the valve stem oil
seal (222). 5. Install the valve spring (223). 6. Install the valve spring cap (224).
7. Compress the valve spring using the J 38606 . 8. Install the valve keys.
* Use grease in order to hold the valve keys in place.
* Make sure the keys seat properly in the groove of the valve stem.
* Carefully release the valve spring pressure, making sure the valve keys stay in place.
* Remove the J 38606 .
* Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions > Page 1919
9. Remove the J 22794 from the spark plug port.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
10. Hand start the spark plug.
Tighten the spark plug to 15 Nm (11 lb ft).
11. Install the spark plug wires at the ignition coil. 12. Install the spark plug wire to the spark plug.
13. Inspect the wires for proper installation:
* Push sideways on each boot in order to check for proper installation.
* Reinstall any loose boot.
14. Install the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Rocker
Arm Assembly/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics
Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics
INFORMATION
Bulletin No.: 08-06-01-008A
Date: July 27, 2009
Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of
Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt
Models:
2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 Vehicles 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add a model year and update the Tool Information.
Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine).
Background
Several aftermarket companies offer laser alignment tools for accessory drive systems that can be
very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges
from $160 - $200.
EN-49228 Laser Alignment Tool - Drive Belt
The GM Tool program has now made available a competitive, simple to use and time-saving laser
tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the
guesswork from proper pulley alignment and may serve to reduce comebacks from:
- Drive Belt Noise
- Accelerated Drive Belt Wear
- Drive Belt Slippage
Instructions
The instructions below are specific only to the truck Gen IV V-8 family of engines. These
instructions are only for illustrative purposes to show how the tool may be used. Universal
instructions are included in the box with the Laser Alignment Tool - Drive Belt.
Caution
- Do not look directly into the beam projected from the laser.
- Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses
help reduce laser beam glare in many circumstances.
- Always use laser safety glasses when using the laser. Laser safety glasses are not designed to
protect eyes from direct laser exposure.
1. Observe and mark the serpentine belt orientation.
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Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page
1925
2. Remove the serpentine belt from the accessory drive system.
3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves
of the pulley, farthest from the front of the
engine.
4. Install the retaining cord around the pulley and to the legs of the tool.
5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the
tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light
beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley
alignment.
- If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly.
- If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the
position of the power steering pulley as required.
- Refer to SI for Power Steering Pulley Removal and Installation procedures.
9. Install the serpentine belt to the accessory drive system in the original orientation.
10. Operate the vehicle and verify that the belt noise concern is no longer present.
Tool Information
Please visit the GM service tool website for pricing information or to place your order for this tool.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page
1926
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 1927
Drive Belt: Service Precautions
Belt Dressing Caution
Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the
composition of the drive belt. Failure to follow this recommendation will damage the drive belt.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 1928
Drive Belt: Description and Operation
Drive Belt System Description
The drive belt system consists of the following components:
* The drive belt
* The drive belt tensioner
* The drive belt idler pulley
* The crankshaft balancer pulley
* The accessory drive component mounting brackets
* The accessory drive components
- The power steering pump
- The generator
- The A/C compressor
- The engine cooling fan
- The water pump, if belt driven
The drive belt system may use 2 belts. The drive belt (1) is thin so that it can bend backwards and
has several ribs to match the grooves in the pulleys. The drive belts are made of different types of
rubbers - chloroprene or EPDM - and have different layers or plies containing either fiber cloth or
cords for reinforcement.
Both sides of the drive belt may be used to drive the different accessory drive components. When
the back side of the drive belt is used to drive a pulley, the pulley is smooth.
The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component
pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent
the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the
drive belt by the accessory drive components and the crankshaft.
The drive belt system has an idler pulley, which is used to add wrap to the adjacent pulleys.
A/C Compressor Drive Belt
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 1929
The outward appearance of the belt (1) is similar to the current design serpentine belt. The
reinforcing cord provides its unique qualities. The belt cord is made of a polyamid material. The
polyamid cord is more elastic than the more traditional aramid or polyester cord designs. A
tensioner is not needed.
Polyamid cord, when combined with a more elastic backing compound, ensures the belt is able to
maintain the specified tension within the specified range of usage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Chirping, Squeal, and Whine Diagnosis
Diagnostic Aids
* A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It
may be necessary to spray a small amount of water on the drive belts in order to duplicate the
customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt
pulleys may be the probable solution.
* If the noise is intermittent, verify the accessory drive components by varying their loads making
sure they are operated to their maximum capacity. An overcharged A/C system, power steering
system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
* A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or
suspension component. Other items of the vehicle may also cause the noise.
* The drive belts will not cause a whine noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be
engine related. This step is to verify that the engine is making the noise. If the engine is not making
the noise do not proceed further with this table. 3. The noise may be an internal engine noise.
Removing the drive belts one at a time and operating the engine for a brief period will verify the
noise is related to the drive belt. When removing the drive belt the water pump may not be
operating and the engine may overheat. Also DTCs may set when the engine is operating with the
drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it
can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of
the pulleys may be caused from improper mounting of the accessory drive component, incorrect
installation of the accessory drive component pulley, or the pulley bent inward or outward from a
previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two
or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the
proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the
possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for
being bent should include inspecting for a dent or other damage to the pulleys that would prevent
the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a
pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the
drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper
belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal
noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt
tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be
routed properly and may be turning an accessory drive component in the wrong direction. 16.
Misalignment of the pulleys may be caused from improper mounting of the accessory drive
component, incorrect installation of the accessory drive component pulley, or the pulley bent inward
or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley
grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive
component for the proper installation procedure for that pulley. 17. This test is to verify that the
pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes.
19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a
temporary repair.
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Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
1932
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
1933
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
1934
Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Vibration from the engine
operating may cause a body component or another part of the vehicle to make rumbling noise.
Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the
power steering system restricted or the incorrect fluid, or an extra load on the generator. To help
identify an intermittent or an improper condition, vary the loads on the accessory drive components.
The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the
drive belt may be the only repair for the symptom.
If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the
drive belts are installed, there might be an accessory drive component with a failure. Varying the
load on the different accessory drive components may aid in identifying which component is
causing the rumbling noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that
the symptom is present during diagnosing. Other vehicle components may cause a similar
symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or
vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the
description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When
removing the drive belts the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive
belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt
will not cause the noise. Belt separation is identified by the plys of the belt separating and may be
seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is normal
condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface
for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt,
nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is
driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump
bearings for smooth operation and excessive play. Compare the water pump with a known good
water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put
extra strain on that accessory component causing it to vibrate.
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Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
1935
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Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
1936
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Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
1937
Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Diagnostic Aids
If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the
drive belt to fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on
the drive belt.
Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt
for the application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause
the drive belt to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the
drive belt fall off.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify
the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off.
The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for
cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be
caused from improper mounting of the accessory drive component, incorrect installation of the
accessory drive component pulley, or the pulley bent inward or outward from a previous repair.
Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys.
If a misaligned pulley is found refer to that accessory drive component for the proper installation
procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a
dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all
of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to
drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive
belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut ,
spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley
misalignment from the bracket moving under load. Over tightening of the fasteners may cause
misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is
correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by
mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is
too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the
grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any
parts of the engine or body while the engine is operating. There should be sufficient clearance
when the drive belt accessory drive components load varies. The drive belt should not come in
contact with an engine or a body component when snapping the throttle.
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Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
1938
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory
Drive Belt: Service and Repair Drive Belt Replacement - Accessory
Drive Belt Replacement - Accessory
Removal Procedure
1. Open the hood. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet
Duct Replacement (See: Tune-up and Engine Performance Checks/Air
Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair).
3. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 4. Rotate the drive belt
tensioner clockwise in order to relieve tension on the belt. 5. Remove the drive belt (1) from the
pulleys and the drive belt tensioner. 6. Slowly release the tension on the drive belt tensioner. 7.
Remove the breaker bar and socket and from the drive belt tensioner bolt. 8. Clean and inspect the
belt surfaces of all the pulleys.
Installation Procedure
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Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1941
1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar
with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to
relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release
the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner
bolt. 7. Inspect the drive belt for proper installation and alignment. 8. Install the air cleaner outlet
duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine
Performance Checks/Air
Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair).
9. Start the vehicle and inspect the drive belt for proper operation.
10. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1942
Drive Belt: Service and Repair Air Conditioning Compressor Belt Replacement
Air Conditioning Compressor Belt Replacement
Removal Procedure
1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt
Replacement - Accessory). 2. Remove the cooling fan. Refer to Fan Replacement (LH8) (See:
Cooling System/Radiator Cooling Fan/Service and Repair)Fan Replacement
(LLV, LLR) (See: Cooling System/Radiator Cooling Fan/Service and Repair).
3. Cut the belt (1) from air conditioning (A/C) and crankshaft pulleys.
Installation Procedure
1. Position the belt behind the rear face of the balancer (1) and off of the A/C pulley (2). 2. Install
the belt installation tool (3) onto the balancer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1943
3. Slide the belt installation tool (1) upward, installing the belt (2) onto the belt installation tool. 4.
Slide the belt installation tool downward, positioning the belt onto the A/C pulley, applying light
tension to the belt.
5. Position the lower portion of the belt (1) with the ribbed area facing forward.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1944
6. Slowly rotate the crankshaft pulley (1) in a clockwise direction while using finger pressure to pull
the belt (2) forward. Ensure that the ribbed area
of the belt remains facing forward and the belt aligns properly to the A/C pulley.
7. Inspect the drive belt (1) for proper installation and alignment.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1945
8. Rotate the balancer (1) and additional 360 degrees to ensure proper belt installation. 9. Install
the cooling fan. Refer to Fan Replacement (LH8) (See: Cooling System/Radiator Cooling
Fan/Service and Repair)Fan Replacement (LLV,
LLR) (See: Cooling System/Radiator Cooling Fan/Service and Repair).
10. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt
Replacement - Accessory).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt Tensioner > Component Information > Testing and Inspection
Drive Belt Tensioner: Testing and Inspection
Drive Belt Tensioner Diagnosis
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt Tensioner > Component Information > Testing and Inspection > Page 1949
Drive Belt Tensioner: Service and Repair
Drive Belt Tensioner Replacement - Accessory
Removal Procedure
1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive
Belt/Service and Repair/Drive Belt Replacement Accessory).
2. Remove the drive belt tensioner bolts. 3. Remove the drive belt tensioner.
Installation Procedure
1. Position the drive belt tensioner to the water pump.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt Tensioner > Component Information > Testing and Inspection > Page 1950
2. Install and tighten the drive belt tensioner bolts.
Tighten the bolts to 50 Nm (37 lb ft).
3. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive
Belt/Service and Repair/Drive Belt Replacement Accessory).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Testing and Inspection
Engine Mount: Testing and Inspection
Engine Mount Inspection
Caution: Broken or deteriorated mounts can cause misalignment and destruction of certain drive
train components. When a single mount breaks, the remaining mounts are subjected to abnormally
high stresses.
Caution: When raising or supporting the engine for any reason, do not use a jack under the oil pan,
any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the
oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump
screen. This will result in a damaged oil pickup unit.
Visual/Physical Inspection
1. Support the powertrain using the appropriate support method; refer to the powertrain mount
replacement procedure. Raising the powertrain
removes the weight from the engine mount and creates slight tension in the rubber.
2. Clean the mount and surrounding area to ensure good visibility of the mount condition. 3. Verify
all attaching fasteners are present and at the correct torque. Refer to Engine Mount Replacement Left Side (See: Service and Repair)
and/or Engine Mount Replacement - Right Side (See: Service and Repair) for any torque
sequencing and/or torque specifications.
Note: Observe the engine mount while raising the engine. If the engine mount exhibits any of the
following conditions the mount may require replacement. Refer to Engine Mount Replacement Left Side (See: Service and Repair) and/or Engine Mount Replacement - Right Side (See: Service
and Repair).
4. Slightly raise the engine approximately 5-7 mm. 5. Inspect the mount for any of the following
conditions:
* Hard rubber surfaces - covered with extreme heat check cracks.
* Rubber separation from the metal plate of the engine mount.
* Rubber is split through the center of the engine mount.
Note: Before replacing any engine mount due to suspected fluid loss, verify that the source of the
fluid is from the engine mount , and not the engine or an external source.
* If equipped with a hydraulic mount, inspect for GLYCOL(TM) fluid leaking from the engine mount.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left
Engine Mount: Service and Repair Engine Mount Replacement - Left
Engine Mount Replacement - Left Side
Removal Procedure
Caution: When raising or supporting the engine for any reason, do not use a jack under the oil pan,
any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the
oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump
screen. This will result in a damaged oil pickup unit.
1. Remove the front tire and wheel. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair). 2. Remove the left exhaust manifold. Refer to
Exhaust Manifold Replacement - Left Side (LH8) (See: Exhaust System/Exhaust Manifold/Service
and Repair/Exhaust Manifold Replacement - Left Side).
3. Remove the engine mount to frame bolts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1956
Note: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan.
4. Place an adjustable (screw type) jack to the tab (1) located on the engine block.
5. Working through the wheelhouse opening, remove the engine mount to engine bolts (1). 6.
Using the adjustable jack, raise the engine slightly until there is enough clearance to remove the
engine mount.
7. Remove the engine mount.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1957
1. Position the engine mount to the engine.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Working through the wheelhouse opening, install the engine mount to engine nuts (1) and
tighten to 55 Nm (41 lb ft). 3. Using the adjustable jack, lower the engine until the engine mount is
sitting flush on the frame. 4. Remove the adjustable jack from the engine block.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1958
5. Install the engine mount to frame bolts (1) and tighten to 65 Nm (48 lb ft) starting with the middle
bolt then either side bolt. 6. Install the left exhaust manifold. Refer to Exhaust Manifold
Replacement - Left Side (LH8) (See: Exhaust System/Exhaust Manifold/Service and
Repair/Exhaust Manifold Replacement - Left Side).
7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1959
Engine Mount: Service and Repair Engine Mount Replacement - Right
Engine Mount Replacement - Right Side
Removal Procedure
Caution: When raising or supporting the engine for any reason, do not use a jack under the oil pan,
any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the
oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump
screen. This will result in a damaged oil pickup unit.
1. Remove the front tire and wheels. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair). 2. Remove the right side exhaust manifold.
Refer to Exhaust Manifold Replacement - Right Side (LH8) (See: Exhaust System/Exhaust
Manifold/Service and Repair/Exhaust Manifold Replacement - Right Side).
3. Unbolt the air conditioning compressor and position aside. Refer to Air Conditioning Compressor
Replacement (LH8) (See: Heating and Air
Conditioning/Compressor HVAC/Service and Repair)Air Conditioning Compressor Replacement
(LLV, LLR) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair).
4. Remove the air conditioning bracket bolts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1960
5. Remove the engine mount to frame bolts (1).
Note: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan.
6. Place an adjustable (screw type) jack to the tab (1) located on the engine block.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1961
7. Remove the engine mount to engine bolts (1). 8. Using the adjustable jack, raise the engine
slightly until there is enough clearance to remove the engine mount.
9. Remove the engine mount (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1962
1. Position the engine mount (1) to the engine.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the engine mount to engine nuts (1) and tighten to 55 Nm (41 lb ft). 3. Using the
adjustable jack, lower the engine until the engine mount is sitting flush on the frame. 4. Remove the
adjustable jack from the engine block.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1963
5. Install the air conditioning compressor bracket bolts (1). 6. Install the air conditioning
compressor. Refer to Air Conditioning Compressor Replacement (LH8) (See: Heating and Air
Conditioning/Compressor HVAC/Service and Repair)Air Conditioning Compressor Replacement
(LLV, LLR) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair).
7. Install the engine mount to frame bolts (1) and tighten to 65 Nm (48 lb ft) starting with the middle
bolt then either side bolt. 8. Install the right side exhaust manifold. Refer to Exhaust Manifold
Replacement - Right Side (LH8) (See: Exhaust System/Exhaust
Manifold/Service and Repair/Exhaust Manifold Replacement - Right Side).
9. Install the front tire and wheels. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair).
10. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Service and Repair
Idler Pulley: Service and Repair
Drive Belt Idler Pulley Replacement
Removal Procedure
1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive
Belt/Service and Repair/Drive Belt Replacement -
Accessory).
2. Loosen the drive belt idler pulley bolt and remove the idler pulley.
Installation Procedure
1. Position the drive belt idler pulley to the generator bracket and tighten the idler pulley bolt finger
tight.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Tighten the drive belt idler pulley bolt.
Tighten the bolt to 50 Nm (37 lb ft).
3. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive
Belt/Service and Repair/Drive Belt Replacement Accessory).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications
Engine Oil Pressure: Specifications
OIL PRESSURE
Oil Pressure - Minimum - Hot..................................................................................................41 kPa
at 1,000 engine RPM (124 kPa at 2,000 engine RPM) Oil Pressure - Minimum Hot...................................................................................................165 kPa at 4,000 engine RPM (6
psig at 1,000 engine RPM) Oil Pressure - Minimum Hot...................................................................................................18 psig at 2,000 engine RPM (24
psig at 4,000 engine RPM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications > Page 1971
Engine Oil Pressure: Testing and Inspection
Oil Pressure Diagnosis and Testing
Tools Required
* EN-47971 Oil Pressure Gage Adapter
* J 21867 Pressure Gage
1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down
time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil
and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine
briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a
noisy valve train or a knocking noise. 5. Inspect for the following conditions:
* Oil diluted by water or glycol antifreeze Refer to Coolant in Engine Oil (See: Testing and
Inspection/Symptom Related Diagnostic Procedures/Coolant in Engine Oil).
* Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal
6. Remove the oil filter and install the EN-47971 (1). 7. Install the J 21867 (2), or equivalent to the
EN-47971 (1). 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to
Engine Mechanical Specifications (See: Specifications/Service Limit & General Specifications).
10. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the
following conditions:
* Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection (See: Service and
Repair/Overhaul).
* Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector
Installation (See: Service and Repair/Overhaul).
* Oil pump screen loose, plugged, or damaged
* Oil pump screen O-ring seal missing or damaged
* Malfunctioning oil pump pressure relief valve
* Excessive bearing clearance
* Cracked, porous, or restricted oil galleries
* Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation (See:
Service and Repair/Overhaul).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip
Stick Tube > Component Information > Service and Repair
Engine Oil Dip Stick - Dip Stick Tube: Service and Repair
Oil Level Indicator and Tube Replacement
Removal Procedure
1. Remove the cylinder number 2 spark plug and wire. Refer to Spark Plug Replacement (See:
Tune-up and Engine Performance Checks/Spark
Plug/Service and Repair).
2. Remove the oil level indicator from the tube. 3. Remove the oil level indicator tube bolt. 4.
Remove the oil level indicator tube from the engine block.
Note: The O-ring seal may be reused if not cut or damaged.
5. Inspect the O-ring seal for cuts or damage. 6. Remove the O-ring seal from the tube, if required.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip
Stick Tube > Component Information > Service and Repair > Page 1975
1. Lubricate the O-ring seal with clean engine oil. 2. Install the O-ring seal onto the oil level
indicator tube. 3. Install the oil level indicator tube behind the exhaust manifold. 4. Raise and
suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 5. Install the oil level indicator tube into the block. Install the tube with
the collar flush to the block. 6. Lower the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. Install the oil level indicator tube bolt.
Tighten the bolt to 25 Nm (18 lb ft).
8. Install the oil level indicator to the tube. 9. Install the cylinder number 2 spark plug and wire.
Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark
Plug/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications
Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications
INFORMATION
Bulletin No.: 11-00-90-001
Date: March 14, 2011
Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for
Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or
Complete Oil Change
Models:
2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with
Duramax(TM) Diesel Engines
GM dexos 1(TM) Information Center Website
Refer to the following General Motors website for dexos 1(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 1(TM) Engine Oil Trademark and Icons
The dexos(TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM)
specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
1(TM) engine oil.
GM dexos 1(TM) Engine Oil Specification
Important General Motors dexos 1(TM) engine oil specification replaces the previous General
Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The
oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains
acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be
used in those older vehicles.
In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine
oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil
specification are as follows:
- To meet environmental goals such as increasing fuel efficiency and reducing engine emissions.
- To promote long engine life.
- To minimize the number of engine oil changes in order to help meet the goal of lessening the
industry's overall dependence on crude oil.
dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the
following benefits:
- Further improve fuel economy, to meet future corporate average fuel economy (CAFE)
requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits
throughout the life of the oil.
- More robust formulations for added engine protection and aeration performance.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1980
- Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life
has been depleted.
- Reduce the duplication of requirements for a large number of internal GM engine oil
specifications.
International Lubricants Standardization and Approval Committee (ILSAC)
GF-5 Standard
In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval
Committee (ILSAC) standard called GF-5, was introduced in October 2010.
- There will be a corresponding API category, called: SN Resource Conserving. The current GF-4
standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos
1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a
statistically significant increase in fuel economy versus the Sequence VIB test that was used for
GF-4.
- It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard.
However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification.
- Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API
will begin licensing marketers during October 2010, to produce and distribute GF-5 certified
products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils.
Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy
Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than
doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed
CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet
these future requirements, all aspects of vehicle operation are being looked at more critically than
ever before.
New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel
economy include direct injection, cam phasing, turbocharging and active fuel management (AFM).
The demands of these new technologies on engine oil also are taken into consideration when
determining new oil specifications. AFM for example can help to achieve improved fuel economy.
However alternately deactivating and activating the cylinders by not allowing the intake and
exhaust valves to open contributes to additional stress on the engine oil.
Another industry trend for meeting tough fuel economy mandates has been a shift toward lower
viscosity oils.
dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs:
SAE 0W-20, 5W-20, 0W-30 and 5W-30.
Using the right viscosity grade oil is critical for proper engine performance. Always refer to the
Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being
serviced.
GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals
To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the
GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000
mile (4,830 km) recommendation.
The dexos (TM) specification, with its requirements for improved oil robustness, compliments the
GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle.
If all GM customers with GM Oil Life System equipped vehicles would use the system as intended,
GM estimates that more than 100 million gallons of oil could be saved annually.
GM dexos 2(TM) Information Center Website
Refer to the following General Motors website for dexos 2(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 2(TM) Engine Oil Trademark and Icons
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1981
The dexos (TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos (TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos
(TM)specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
2(TM) engine oil.
GM dexos 2(TM) Engine Oil Specification
- dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010
vehicles, regardless of where the vehicle was manufactured.
- dexos 2(TM) is the recommended service fill oil for European gasoline engines.
Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting
specification CJ-4.
- dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and
replaces GM-LL-B-025 and GM-LL-A-025.
- dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on
certain chemical components to prolong catalyst life and protect expensive emission reduction
systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum
performance longer.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil with Filter ............................................................................................................................
............................................... 6.0 quarts (5.7 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 1984
Engine Oil: Fluid Type Specifications
ENGINE OIL
Look for three things:
1. Use only an oil that meets GM Standard GM6094M.
2. Temperatures above -20°F (-29°C), SAE 5W-30 is best for the vehicle. These numbers on an oil
container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 10W-40,
SAE 20W-50 or any other viscosity grade oil not recommended.
3. American Petroleum Institute (API) starburst symbol
Oils meeting these requirements should have the starburst symbol on the container. This symbol
indicates that the oil has been certified by the American Petroleum Institute (API).
Notice: Use only engine oil identified as meeting GM Standard GM6094M and showing the
American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the
recommended oil can result in engine damage not covered by the vehicle warranty.
COLD TEMPERATURE OPERATION If in an area of extreme cold, where the temperature falls
below -20°F (-29°C), use either an SAE 5W-30 synthetic oil or an SAE 0W-30 engine oil. Both
provide easier cold starting for the engine at extremely low temperatures. Always use an oil that
meets the required specification, GM6094M.
ENGINE OIL ADDITIVES / ENGINE OIL FLUSHES Do not add anything to the oil. The
recommended oils with the starburst symbol that meet GM Standard GM6094M are all that is
needed for good performance and engine protection.
Engine oil system flushes are not recommended and could cause engine damage not covered by
the vehicle warranty.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 1985
Engine Oil: Service and Repair
Engine Oil and Oil Filter Replacement
Removal Procedure
1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Place a
oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to
drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and
inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from
the drain plug hole and reinstall the oil pan drain plug until snug.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 1986
10. Position the drain pan under the oil filter. 11. Remove the oil filter. 12. Ensure that the oil filter
gasket is still on the old filter if not, remove the oil filter gasket from the oil pan.
Installation Procedure
1. Apply clean engine oil to the NEW oil filter seal.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the NEW oil filter.
Tighten the oil filter to 30 Nm (22 lb ft).
3. Tighten the oil pan drain plug.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 1987
Tighten the drain plug to 25 Nm (18 lb ft).
4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new
engine oil. Refer to Approximate Fluid Capacities (See: Maintenance/Service Intervals) and Fluid
and Lubricant
Recommendations (See: Maintenance/Service Intervals).
7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the
oil a few minutes to drain back into the oil pan.
10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil
level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level
indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13.
Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level
indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary,
adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance
Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance
INFORMATION
Bulletin No.: 07-06-01-016B
Date: July 27, 2009
Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin
Number 07-06-01-016A (Section 06 - Engine/Propulsion System).
Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is
not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R)
oil filters directly from GMSPO.
Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the
most recent parts information to ensure the correct part number filter is installed when replacing oil
filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been
discovered in some aftermarket parts systems. Always ensure the parts you install are from a
trusted source. Improper oil filter installation may result in catastrophic engine damage.
Refer to the appropriate Service Information (SI) installation instructions when replacing any oil
filter and pay particular attention to procedures for proper cartridge filter element alignment. If the
diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise
or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number
02-00-89-002I (Information for Dealers on How to Submit a Field Product Report).
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > Page 1992
Oil Filter: Service and Repair
Engine Oil and Oil Filter Replacement
Removal Procedure
1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Place a
oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to
drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and
inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from
the drain plug hole and reinstall the oil pan drain plug until snug.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > Page 1993
10. Position the drain pan under the oil filter. 11. Remove the oil filter. 12. Ensure that the oil filter
gasket is still on the old filter if not, remove the oil filter gasket from the oil pan.
Installation Procedure
1. Apply clean engine oil to the NEW oil filter seal.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the NEW oil filter.
Tighten the oil filter to 30 Nm (22 lb ft).
3. Tighten the oil pan drain plug.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > Page 1994
Tighten the drain plug to 25 Nm (18 lb ft).
4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new
engine oil. Refer to Approximate Fluid Capacities (See: Maintenance/Service Intervals) and Fluid
and Lubricant
Recommendations (See: Maintenance/Service Intervals).
7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the
oil a few minutes to drain back into the oil pan.
10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil
level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level
indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13.
Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level
indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary,
adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter >
Component Information > Service and Repair
Oil Filter Adapter: Service and Repair
Oil Filter Adapter Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Place a suitable drain pan under the oil filter. 3.
Remove the oil filter (437).
4. Remove the oil filter adapter (438).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter >
Component Information > Service and Repair > Page 1998
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the oil filter adapter (438).
Tighten the adapter to 55 Nm (40 lb ft).
2. Lubricate the oil filter seal with clean engine oil. 3. Install the oil filter (437).
Tighten the filter to 30 Nm (22 lb ft).
4. Lower the vehicle. 5. Refill the engine oil. Refer to Approximate Fluid Capacities (See:
Maintenance/Service Intervals) and/or Fluid and Lubricant Recommendations
(See: Maintenance/Service Intervals).
6. Start the engine and inspect for leaks.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications
Oil Pan: Specifications
OIL PAN
Oil Pan M6 Bolts - Oil Pan-to-Rear Housing........................................................................................
.......................................................12 Nm (106 lb in) Oil Pan M8 Bolts - Oil Pan-to-Engine Block
and Oil Pan-to-Front Cover.....................................................................................................25 Nm
(18 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 2002
Oil Pan: Service and Repair
Oil Pan Replacement
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
2. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement (See:
Engine Oil Dip Stick - Dip Stick Tube/Service and
Repair).
3. Remove the front differential, if equipped. Refer to Differential Carrier Assembly Replacement
(See: Transmission and Drivetrain/Differential
Assembly/Differential Carrier/Service and Repair).
4. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement (See: Engine Oil/Service
and Repair). 5. Remove the transmission oil cooler lines (1) from the retainer (2). 6. Remove the
transmission oil cooler line retaining bracket bolt (3) and bracket (4). 7. Remove the inner axle
shaft. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (See:
Transmission and
Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Front Drive
Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement).
8. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and
Charging/Starting System/Starter Motor/Service and
Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
9. Remove the flywheel inspection cover from the left side of the transmission.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 2003
10. Remove the battery cable channel bolt from the front of the oil pan. 11. Remove the battery
cable channel from the oil pan.
12. Loosen the 2 upper air conditioning (A/C) compressor bracket bolts (4). 13. Remove the 2
lower A/C compressor bracket bolts (3).
Position the A/C compressor aside and secure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 2004
14. Remove the 2 lower bellhousing bolts (1).
15. Remove the oil pan bolts (1). 16. Remove the oil pan by tilting the rear of the oil pan down to
clear the transmission, pull the oil pan rearward past the front wire harness, then lower
the oil pan clear of the vehicle.
Note: *
The oil pan gasket is reusable. It is NOT necessary to remove the oil pan gasket unless damaged.
* DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings
as required.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 2005
17. Drill out the oil pan gasket retaining rivets (2), if required. 18. Remove the gasket (1) from the
pan. 19. Discard the gasket and rivets. 20. Clean and inspect the oil pan. Refer to Automatic
Transmission Flex Plate Cleaning and Inspection ().
Installation Procedure
Note:
* The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide
mounting points for the transmission bellhousing. To ensure the rigidity of the powertrain and
correct transmission alignment, it is important that the rear of the block and the rear of the oil pan
must NEVER protrude beyond the engine block and transmission bellhousing plane.
* If replacing the oil pan gasket it is not necessary to rivet the NEW gasket to the oil pan.
1. Apply a 5 mm (0.2 in) bead of sealant 20 mm (0.8 in) long to the engine block. Refer to
Adhesives, Fluids, Lubricants, and Sealers (See:
Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Apply the
sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface.
2. Apply a 5 mm (0.2 in) bead of sealant 20 mm (0.8 in) long to the engine block. Refer to
Adhesives, Fluids, Lubricants, and Sealers (See:
Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Apply the
sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 2006
3. Pre-assemble the oil pan gasket and bolts (1) to the pan.
* Install the gasket onto the pan.
* Install the oil pan bolts to the pan and through the gasket.
4. Install the oil pan, oil pan gasket, and bolts to the engine block as an assembly. 5. Hand thread
the oil pan bolts into the engine block until snug. Do not tighten at this time.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the 2 lower bellhousing bolts (1).
* Tighten the lower bellhousing bolts to 50 Nm (37 lb ft).
* Tighten the 2 rear oil pan to rear cover bolts to 12 Nm (106 lb in).
* Tighten the remaining oil pan bolts to 25 Nm (18 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 2007
7. Install the 2 lower A/C compressor bracket bolts (3) and tighten to 50 Nm (37 lb ft). 8. Tighten
the 2 upper A/C compressor bracket bolts (4) to 50 Nm (37 lb ft).
9. Install the battery cable channel to the oil pan.
10. Install the battery cable channel bolt to the oil pan and tighten the bolt to 12 Nm (106 lb in). 11.
Install the flywheel inspection cover to the left side of the transmission.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 2008
12. Install the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and
Charging/Starting System/Starter Motor/Service and Repair
)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
13. Install the inner axle shaft. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing
Replacement (See: Transmission and
Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Front Drive
Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement).
14. Install the transmission oil cooler line retaining bracket (4) and bolt (3) and tighten to 9 Nm (80
lb in). 15. Install the transmission oil cooler lines (1) to the retainer (2). 16. Install the oil level
indicator tube. Refer to Oil Level Indicator and Tube Replacement (See: Engine Oil Dip Stick - Dip
Stick Tube/Service and
Repair).
17. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement (See: Engine Oil/Service
and Repair). 18. Install the front differential, if equipped. Refer to Differential Carrier Assembly
Replacement (See: Transmission and Drivetrain/Differential
Assembly/Differential Carrier/Service and Repair).
19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Starting and Charging/Battery/Battery
Cable/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations
Oil Pressure Sender: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations > Page 2012
Oil Pressure Sender: Diagrams
Component Connector End Views
Engine Oil Pressure (EOP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor >
Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Special Tools
J 41712 Oil Pressure Switch Socket
Removal Procedure
1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Intake
Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil
pressure sensor.
3. If not equipped with active fuel management perform the following step, using J 41712 or
equivalent, remove the oil pressure sensor (706) and
washer (707).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor >
Component Information > Service and Repair > Page 2016
4. If equipped with active fuel management perform the following step, using J 41712 or equivalent,
remove the oil pressure sensor (706) and
washer (707).
Installation Procedure
1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids,
Lubricants, and Sealers (See: Specifications/Adhesives,
Fluids, Lubricants, and Sealers).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. If equipped with active fuel management perform the following step, using J 41712 or equivalent.
Install the oil pressure sensor (706) and washer
(707). Tighten the sensor to 35 Nm (26 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor >
Component Information > Service and Repair > Page 2017
3. If not equipped with active fuel management, perform the following step, using J 41712 or
equivalent. Install the oil pressure sensor (706) and
washer (707).
4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the
sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement
(See: Intake Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine
Oil Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
OIL PRESSURE
Oil Pressure - Minimum - Hot..................................................................................................41 kPa
at 1,000 engine RPM (124 kPa at 2,000 engine RPM) Oil Pressure - Minimum Hot...................................................................................................165 kPa at 4,000 engine RPM (6
psig at 1,000 engine RPM) Oil Pressure - Minimum Hot...................................................................................................18 psig at 2,000 engine RPM (24
psig at 4,000 engine RPM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine
Oil Pressure > Component Information > Specifications > Page 2022
Engine Oil Pressure: Testing and Inspection
Oil Pressure Diagnosis and Testing
Tools Required
* EN-47971 Oil Pressure Gage Adapter
* J 21867 Pressure Gage
1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down
time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil
and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine
briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a
noisy valve train or a knocking noise. 5. Inspect for the following conditions:
* Oil diluted by water or glycol antifreeze Refer to Coolant in Engine Oil (See: Testing and
Inspection/Symptom Related Diagnostic Procedures/Coolant in Engine Oil).
* Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal
6. Remove the oil filter and install the EN-47971 (1). 7. Install the J 21867 (2), or equivalent to the
EN-47971 (1). 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to
Engine Mechanical Specifications (See: Specifications/Service Limit & General Specifications).
10. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the
following conditions:
* Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection (See: Service and
Repair/Overhaul).
* Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector
Installation (See: Service and Repair/Overhaul).
* Oil pump screen loose, plugged, or damaged
* Oil pump screen O-ring seal missing or damaged
* Malfunctioning oil pump pressure relief valve
* Excessive bearing clearance
* Cracked, porous, or restricted oil galleries
* Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation (See:
Service and Repair/Overhaul).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement
Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement
INFORMATION
Bulletin No.: 00-06-01-026C
Date: February 03, 2010
Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to include additional model years. Please discard
Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine).
When replacing an engine due to internal damage, extreme care should be taken when transferring
the intake manifold to the new Goodwrench service engine long block. Internal damage may result
in the potential discharge of internal engine component debris in the intake manifold via broken
pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the
engine, the technician should carefully inspect all of the cylinder head intake ports to see if the
valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently
bent, internal engine component debris will be present to varying degrees in the intake port of the
cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold
should be replaced. This replacement is required due to the complex inlet runner and plenum
configuration of most of the intake manifolds, making thorough and complete component cleaning
difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake
manifold removed from an engine with deposits of internal engine component debris may result in
the ingestion of any remaining debris into the new Goodwrench service engine. This may cause
damage or potential failure of the new service engine.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Technical Service Bulletins > Page 2027
Intake Manifold: Specifications
INTAKE MANIFOLD
Intake Manifold Bolts First Pass in Sequence......................................................................................
..............................................................................................5 Nm (44 lb in) Final Pass in Sequence.
..............................................................................................................................................................
..................10 Nm (89 lb in)
THROTTLE BODY
Throttle Body Bolts...............................................................................................................................
.........................................................10 Nm (89 lb in) Throttle Body Nuts............................................
.............................................................................................................................................10 Nm (89
lb in)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement
Intake Manifold: Service and Repair Intake Manifold Replacement
Intake Manifold Replacement
Removal Procedure
1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Tune-up and Engine Performance Checks/Air
Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair).
2. Remove the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and
Charging/Charging System/Alternator/Service and
Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and
Charging/Charging System/Alternator/Service and Repair/Generator Replacement).
3. Remove the engine harness retainer nut (1). 4. Remove the engine harness retainer from the
stud and locator pin. 5. Disconnect the engine harness electrical connector (2) from the evaporative
emission (EVAP) canister purge solenoid. 6. Disconnect the engine wiring harness electrical
connector (3) from the manifold absolute pressure (MAP) sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2030
7. Disconnect the engine harness electrical connector (1) from the ignition coil harness electrical
connector. 8. Disconnect the engine harness electrical connectors (2) from the left side fuel
injectors. 9. Remove the engine harness clip (3) from the ignition coil bracket stud.
10. Disconnect the engine harness electrical connector (1) from the ignition coil harness electrical
connector. 11. Disconnect the engine harness electrical connector (2) from the throttle actuator. 12.
Remove the engine harness clip (3) from the ignition coil bracket stud. 13. Disconnect the engine
harness electrical connectors (4) from the right side fuel injectors.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2031
14. Remove the engine harness clips (1). 15. Disconnect the engine harness electrical connector
(2) from the engine coolant temperature (ECT) sensor. 16. Gather the engine harness branches
and tie the harness up out of the way to the front of the engine compartment.
17. Disconnect the engine oil pressure sensor electrical connector (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2032
18. Reposition the brake booster vacuum hose clamp at the booster. 19. Remove the brake
booster vacuum hose from the booster fitting. 20. Secure the brake booster vacuum hose to the
intake manifold.
21. Disconnect the EVAP canister purge tube (1) quick connect fitting from the EVAP canister
purge solenoid. Refer to Plastic Collar Quick Connect
Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line
Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
22. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar
Quick Connect Fitting Service (See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar
Quick Connect Fitting Service).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2033
23. Remove the positive crankcase ventilation (PCV) hose from the intake manifold fitting. 24.
Position the hose out of the way.
25. Loosen the intake manifold bolts (512).
Note: The aid of an assistant may be helpful in holding the engine harness up out of the way so the
upper intake manifold cover does not get caught against the engine harness.
26. Remove the intake manifold (500). 27. Cover the cylinder head passages in order to prevent
dirt or debris from entering the passages.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2034
28. Remove and discard the intake manifold gaskets (514).
29. If replacing the intake manifold, perform the following steps, otherwise proceed to step 21 of the
installation procedure. 30. Place the intake manifold on a clean work surface. 31. Reposition the
brake booster vacuum hose clamp at the intake manifold. 32. Remove the brake booster vacuum
hose from the intake manifold nipple.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2035
33. Remove the upper intake manifold cover nut. 34. Remove the upper intake manifold cover.
35. Remove the manifold absolute pressure (MAP) sensor retainer. 36. Remove the MAP sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2036
37. Disconnect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar
Quick Connect Fitting Service (See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar
Quick Connect Fitting Service).
38. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail. 39. Remove
the EVAP tube and purge solenoid.
40. Remove the throttle body bolts/nuts. 41. Remove the throttle body. 42. Remove and discard the
throttle body gasket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2037
43. Remove the fuel rail bolts.
Note: Lift evenly on both sides of the fuel rail until all injectors are removed from their bores.
44. Remove the fuel rail. 45. Remove and discard the fuel injector lower O-ring seals.
Note: Evenly push in the RED collar in order to remove the nipple.
46. Remove the brake booster vacuum hose nipple.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2038
1. If the intake manifold was replaced perform the following steps, otherwise proceed to step 21.
Note: Evenly push in the RED collar in order to install the nipple.
2. Install the brake booster vacuum hose nipple to the NEW intake manifold.
3. Install NEW fuel injector lower O-ring seals onto the injectors. 4. Lubricate the NEW O-ring seals
with clean engine oil.
Note: Push down firmly on both sides of the rail until all the injectors have been seated into their
bores.
5. Install the fuel rail.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the fuel rail bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2039
Tighten the bolts to 10 Nm (89 lb in).
7. Install a NEW throttle body gasket to the intake manifold. 8. Install the throttle body. 9. Install the
throttle body bolts/nuts.
Tighten the bolts/nuts to 10 Nm (89 lb in).
10. Install the EVAP tube and purge solenoid. 11. Install the EVAP canister purge solenoid to the
fuel rail bracket and engage the retainer. 12. Connect the EVAP tube quick connect fitting at the
intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar
Quick Connect Fitting Service).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2040
13. Lubricate the MAP sensor seal with clean engine oil. 14. Install the MAP sensor. 15. Install the
MAP sensor retainer.
16. Install the upper intake manifold cover. 17. Install the upper intake manifold cover nut until snug
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2041
18. Install the brake booster vacuum hose to the intake manifold nipple. 19. Position the brake
booster vacuum hose clamp at the intake manifold. 20. Secure the brake booster vacuum hose to
the intake manifold.
21. Install NEW intake manifold gaskets (514) to the intake manifold. 22. Remove the covers from
the cylinder head passages.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2042
23. Install the intake manifold (500).
Note: The aid of an assistant may be helpful in holding the engine harness up out of the way so the
upper intake manifold cover does not get caught against the engine harness.
24. Tighten the intake manifold bolts (512) until snug.
25. Tighten the intake manifold bolts to specifications.
* Tighten the bolts a first pass in the sequence shown to 5 Nm (44 lb in).
* Tighten the bolts a final pass in the sequence shown to 10 Nm (89 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2043
26. Position and install the PCV hose to the intake manifold fitting.
27. Connect the fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick
Connect Fitting Service (See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar
Quick Connect Fitting Service).
28. Connect the EVAP canister purge tube (1) quick connect fitting to the EVAP canister purge
solenoid. Refer to Plastic Collar Quick Connect
Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line
Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2044
29. Unsecure the brake booster vacuum hose from the intake manifold. 30. Install the brake
booster vacuum hose to the booster fitting. 31. Position the brake booster vacuum hose clamp at
the booster.
32. Connect the engine oil pressure sensor electrical connector (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2045
33. Untie the engine harness branches from the front of the engine compartment and position over
the engine. 34. Connect the engine harness electrical connector (2) to the ECT sensor. 35. Position
the engine harness clips (1) to the bracket.
36. Connect the engine harness electrical connectors (4) to the right side fuel injectors. 37. Install
the engine harness clip (3) to the ignition coil bracket stud. 38. Connect the engine harness
electrical connector (2) to the throttle actuator. 39. Connect the engine harness electrical connector
(1) to the ignition coil harness electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2046
40. Install the engine harness clip (3) to the ignition coil bracket stud. 41. Connect the engine
harness electrical connectors (2) to the left side fuel injectors. 42. Connect the engine harness
electrical connector (1) to the ignition coil harness electrical connector. 43. Install the CPA retainer
(1).
44. Connect the engine wiring harness electrical connector (3) to the MAP sensor. 45. Connect the
engine harness electrical connector (2) to the EVAP canister purge solenoid. 46. Install the engine
harness retainer to the stud and locator pin. 47. Install the engine harness retainer nut (1).
Tighten the nut to 5 Nm (44 lb in).
48. Install the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and
Charging/Charging System/Alternator/Service and
Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and
Charging/Charging System/Alternator/Service and Repair/Generator Replacement).
49. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Tune-up and Engine Performance Checks/Air
Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2047
Intake Manifold: Service and Repair Upper Intake Manifold Sight Shield Replacement
Upper Intake Manifold Sight Shield Replacement
Removal Procedure
1. Remove the oil fill cap. 2. Grasp the front of the intake manifold sight shield and lift up
disengaging the grommets from the studs. 3. Remove the intake manifold sight shield from the
retainer slots.
4. Remove the intake manifold sight shield retainer bolts and retainer, if required.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 2048
1. Position the intake manifold sight shield on top of the intake manifold, aligning the holes, if
required.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the intake manifold sight shield retainer bolts, if required.
Tighten the bolts to 5 Nm (44 lb in).
3. Install the intake manifold sight shield tabs into the slots in the retainer. 4. Align the intake
manifold sight shield grommets with the studs. 5. Gently push down on the intake manifold sight
shield over the grommets, seating the intake manifold sight shield. 6. Install the oil fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Service and Repair
Crankshaft Main Bearing Seal: Service and Repair
Crankshaft Rear Oil Seal Replacement
Tools Required
J 41479 Crankshaft Rear Oil Seal Installer
Removal Procedure
1. Remove the automatic transmission flexplate, refer to Automatic Transmission Flex Plate
Replacement (See: Transmission and Drivetrain/Flex
Plate/Service and Repair/Automatic Transmission Flex Plate Replacement).
2. Remove and discard the crankshaft rear oil seal (141).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Service and Repair > Page 2053
Important: For proper orientation, note the installation direction of the oil seal. The oil seal is a
reverse-lip design. The part number is applied to the outside face of the seal, as shown.
1. Inspect the seal and identify the part number markings for proper orientation.
2. Install the J 41479 cone (2) and bolts onto the rear of the crankshaft. 3. Tighten the bolts until
snug. Do not overtighten. 4. Install the rear oil seal onto the tapered cone (2) and push the seal to
the rear seal bore. Install the oil seal with the part number markings facing
away from the engine.
5. Thread the J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal. 6.
Align the oil seal into the tool (1). 7. Rotate the handle of the tool (1) clockwise until the seal enters
the rear cover and bottoms into the cover bore. 8. Remove the J 41479 . 9. Install the automatic
transmission flexplate, refer to Automatic Transmission Flex Plate Replacement (See:
Transmission and Drivetrain/Flex
Plate/Service and Repair/Automatic Transmission Flex Plate Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Service and Repair
Front Crankshaft Seal: Service and Repair
Crankshaft Front Oil Seal Replacement
Special Tools
J 41478 Crankshaft Front Oil Seal Installer
Removal Procedure
1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder
Block Assembly/Harmonic Balancer - Crankshaft
Pulley/Service and Repair).
2. Remove the crankshaft front oil seal (1) from the front cover.
Installation Procedure
Important:
* Do not lubricate the oil seal sealing surface.
* Do not reuse the crankshaft front oil seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Service and Repair > Page 2057
1. Lubricate the outer edge of the oil seal (1) with clean engine oil. 2. Lubricate the front cover oil
seal bore with clean engine oil.
3. Install the crankshaft front oil seal (1) onto the J 41478 guide. 4. Install the J 41478 threaded rod
(with nut, washer, guide, and oil seal) into the end of the crankshaft. 5. Use the J 41478 in order to
install the oil seal into the cover bore.
1. Use a wrench and hold the hex on the installer bolt. 2. Use a second wrench and rotate the
installer nut clockwise until the seal bottoms in the cover bore. 3. Remove the J 41478 . 4. Inspect
the oil seal for proper installation. The oil seal should be installed evenly and completely into the
front cover bore.
6. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block
Assembly/Harmonic Balancer - Crankshaft
Pulley/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair
Valve Guide Seal: Service and Repair
Valve Stem Oil Seal and Valve Spring Replacement
Special Tools
* J 22794 Spark Plug Port Adapter
* J 38606 Valve Spring Compressor
Removal Procedure
1. Remove the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See:
Camshaft, Lifters and Push Rods/Rocker Arm
Assembly/Service and Repair).
2. Disconnect the spark plug wire at the spark plug.
* Twist each plug wire boot 1/2 turn.
* Pull only on the boot in order to remove the wire from the spark plug.
Note: Remove the spark plugs from the cylinder head with the engine at room temperature.
3. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the
spark plug. 5. Remove the spark plug.
6. Install the J 22794 into the spark plug hole. 7. Attach an air hose to the J 22794 . 8. Apply
compressed air to the J 22794 in order to hold the valves in place.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 2061
9. Use the J 38606 in order to compress the valve spring.
10. Remove the valve stem keys (225). 11. Carefully release the valve spring tension. 12. Remove
the J 38606 . 13. Remove the valve spring cap (224). 14. Remove the valve spring (223). 15.
Remove the valve stem oil seal (222). 16. Remove the valve (228).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 2062
1. Clean the cylinder head valve spring seat area. 2. Lubricate the valve guide and valve stem oil
seal with clean engine oil. 3. Install the valves (228) into the proper port. 4. Install the valve stem oil
seal (222). 5. Install the valve spring (223). 6. Install the valve spring cap (224).
7. Compress the valve spring using the J 38606 . 8. Install the valve keys.
* Use grease in order to hold the valve keys in place.
* Make sure the keys seat properly in the groove of the valve stem.
* Carefully release the valve spring pressure, making sure the valve keys stay in place.
* Remove the J 38606 .
* Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 2063
9. Remove the J 22794 from the spark plug port.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
10. Hand start the spark plug.
Tighten the spark plug to 15 Nm (11 lb ft).
11. Install the spark plug wires at the ignition coil. 12. Install the spark plug wire to the spark plug.
13. Inspect the wires for proper installation:
* Push sideways on each boot in order to check for proper installation.
* Reinstall any loose boot.
14. Install the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Camshaft,
Lifters and Push Rods/Rocker Arm
Assembly/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Locations
Oil Pressure Sender: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Locations > Page 2068
Oil Pressure Sender: Diagrams
Component Connector End Views
Engine Oil Pressure (EOP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sensor > Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Special Tools
J 41712 Oil Pressure Switch Socket
Removal Procedure
1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Intake
Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil
pressure sensor.
3. If not equipped with active fuel management perform the following step, using J 41712 or
equivalent, remove the oil pressure sensor (706) and
washer (707).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sensor > Component Information > Service and Repair > Page 2072
4. If equipped with active fuel management perform the following step, using J 41712 or equivalent,
remove the oil pressure sensor (706) and
washer (707).
Installation Procedure
1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids,
Lubricants, and Sealers (See: Specifications/Adhesives,
Fluids, Lubricants, and Sealers).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. If equipped with active fuel management perform the following step, using J 41712 or equivalent.
Install the oil pressure sensor (706) and washer
(707). Tighten the sensor to 35 Nm (26 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sensor > Component Information > Service and Repair > Page 2073
3. If not equipped with active fuel management, perform the following step, using J 41712 or
equivalent. Install the oil pressure sensor (706) and
washer (707).
4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the
sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement
(See: Intake Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
CAMSHAFT GEAR/SPROCKET
Camshaft Sprocket Bolt First Pass.......................................................................................................
................................................................................................75 Nm (55 lb ft) Final Pass...................
..............................................................................................................................................................
..............................50 degrees
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair
Timing Chain: Service and Repair
Camshaft Timing Chain and Sprocket Replacement
Special Tools
* J 8433-1 Puller Bar
* J 41478 Crankshaft Front Oil Seal Installer
* J 41558 Crankshaft Sprocket Remover
* J 41665 Crankshaft Balancer and Sprocket Installer
* J 41816-2 Crankshaft End Protector
Removal Procedure
1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement
(See: Engine Lubrication/Oil Pump/Service and
Repair).
Caution: Do not turn the crankshaft assembly after the timing chain has been removed in order to
prevent damage to the piston assemblies or the valves.
2. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are
aligned.
Caution: Do not turn the crankshaft assembly after the timing chain has been removed in order to
prevent damage to the piston assemblies or the valves.
3. Remove and discard the camshaft sprocket bolt (206). 4. Remove the camshaft sprocket (205)
and timing chain (208).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2081
5. Remove the bolts (231) and timing chain tensioner (232).
6. Use the J 41816-2 (1), the J 41558 (2), bolts (3), and the J 8433 (4) in order to remove the
crankshaft sprocket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2082
7. Remove the crankshaft sprocket (207).
8. Remove the crankshaft sprocket key, as required.
Installation Procedure
1. Install the key into the crankshaft keyway, if previously removed.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2083
2. Tap the key (122) into the keyway until both ends of the key bottom onto the crankshaft.
3. Install the crankshaft sprocket (207) onto the front of the crankshaft. Align the crankshaft key
with the crankshaft sprocket keyway.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2084
4. Use the J 41478 (1) and the J 41665 (2) in order to install the crankshaft sprocket.
Install the sprocket onto the crankshaft until fully seated against the crankshaft flange.
5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position.
6. Compress the timing chain tensioner guide and install the EN 46330 .
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2085
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. Install the timing chain tensioner (232) and bolts (231).
Tighten the timing chain tensioner bolts to 25 Nm (18 lb ft).
Note: *
The sprocket teeth and timing chain must mesh.
* The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly.
8. Install the camshaft sprocket (205), timing chain (208), and bolt (206).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2086
9. Inspect the sprockets for proper alignment. The mark on the camshaft sprocket (1) should be
located in the 6 o'clock position and the mark on the
crankshaft sprocket (2) should be located in the 12 o'clock position.
10. Remove the EN 46330 .
Note: Do not apply threadlock to the flex plate bolts at this time.
11. Temporarily install the automatic transmission flex plate and bolts. Refer to Automatic
Transmission Flex Plate Cleaning and Inspection ().
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2087
12. Install the J 42386-A and bolts. Use 1 M10-1.5 x 120 mm bolt and 1 M10-1.5 x 45 mm bolt for
proper tool operation.
Tighten the J 42386-A bolts to 50 Nm (37 lb ft).
13. Tighten the camshaft sprocket bolt.
1. Tighten the camshaft sprocket bolt a first pass to 75 Nm (55 lb ft). 2. Tighten the camshaft
sprocket bolt a final pass an additional 50 degrees using the J 45059 .
14. Remove the J 42386-A and bolts. 15. Remove the automatic transmission flex plate and bolts.
Refer to Automatic Transmission Flex Plate Removal (). 16. Install the oil pump. Refer to Oil Pump,
Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Specifications
Timing Chain Tensioner: Specifications
Timing Chain Tensioner Bolt................................................................................................................
..........................................................25 Nm (18 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component
Alignment Marks > Component Information > Locations
Timing Component Alignment Marks: Locations
Inspect the sprockets for proper alignment. The mark on the camshaft sprocket (1) should be
located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in
the 12 o'clock position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Timing Cover: Specifications
Engine Front Cover (TIMING COVER)
Front Cover Bolts..................................................................................................................................
..........................................................25 Nm (18 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2097
Timing Cover: Service and Repair
Engine Front Cover Replacement
Special Tools
* J 41476 Front and Rear Cover Alignment Tool
* J 41480 Front and Rear Cover Alignment
Removal Procedure
1. Remove the water pump. Refer to Water Pump Replacement (With LH8) (See: Water
Pump/Service and Repair)Water Pump Replacement (LLV,
LLR) (See: Water Pump/Service and Repair).
2. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder
Block Assembly/Harmonic Balancer - Crankshaft
Pulley/Service and Repair).
3. Disconnect the engine harness electrical connector (1) from the camshaft position (CMP) sensor
wire harness electrical connector.
4. Remove the oil pan-to-front cover bolts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2098
5. Remove the front cover bolts (1). 6. Remove the front cover (2) and gasket (3). 7. Discard the
front cover gasket. 8. Remove the crankshaft front oil seal.
9. If replacing the engine front cover perform the following steps, otherwise proceed to step 10 of
the installation procedure.
10. Remove the CMP sensor wire harness bolts (1, 6). 11. Disconnect the CMP sensor wire
harness from the CMP sensor. 12. Remove the CMP sensor wire harness (5). 13. Remove the
CMP sensor (2).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2099
Note: *
Do not use the crankshaft oil seal or the engine front cover gasket again.
* Do not apply any type of sealant to the front cover gasket, unless specified.
* The special tools in this procedure are used to properly align the engine front cover at the oil pan
surface and to center the crankshaft front oil seal.
- All gasket surfaces should be free of oil or other foreign material during assembly. The crankshaft
front oil seal MUST be centered in relation to the crankshaft.
- The oil pan sealing surface at the front cover and engine block MUST be aligned within
specifications.
- An improperly aligned front cover may cause premature front oil seal wear and/or engine
assembly oil leaks.
1. Install the front cover gasket (3), front cover (2), and bolts (1). 2. Tighten the cover bolts finger
tight. Do not overtighten.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: Start the tool-to-front cover bolts. Do not tighten the bolts at this time.
3. Install the J 41480 .
Tighten the tool-to-engine block bolts to 25 Nm (18 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2100
Note: Align the tapered legs of the tool with the machined alignment surfaces on the front cover.
4. Install the J 41476 . 5. Install the crankshaft balancer bolt.
1. Tighten the crankshaft balancer bolt by hand until snug. Do not overtighten. 2. Tighten the J
41480 . 3. Tighten the engine front cover bolts to 25 Nm (18 lb ft).
6. Remove the tools.
7. Measure the oil pan surface flatness, front cover-to-engine block.
1. Place a straight edge across the engine block and front cover oil pan sealing surfaces.
Avoid contact with the portion of the gasket that protrudes into the oil pan surface.
2. Insert a feeler gage between the front cover and the straight edge tool. The cover must be flush
with the oil pan surface or no greater than 0.5
mm (0.02 in) (a) below flush.
8. If the front cover-to-engine block oil pan surface alignment is not within specifications, repeat the
cover alignment procedure. 9. If the correct front cover-to-engine block alignment cannot be
obtained, replace the front cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2101
10. Inspect the camshaft position (CMP) sensor O-ring seal (3) for cuts or damage. If the seal is not
cut or damaged, it may be used again. 11. Lubricate the O-ring seal with clean engine oil. 12.
Install the O-ring seal onto the sensor (2). 13. Install the sensor to the cover. 14. Install the CMP
sensor wire harness (5) and bolts (1, 6).
Tighten the bolts to 12 Nm (106 lb in).
15. Connect the engine harness electrical connector (1) to the CMP sensor wire harness electrical
connector. 16. Install a NEW crankshaft front oil seal. Refer to Crankshaft Front Oil Seal
Replacement (See: Seals and Gaskets/Front Crankshaft Seal/Service
and Repair).
17. Install the water pump. Refer to Water Pump Replacement (With LH8) (See: Water
Pump/Service and Repair)Water Pump Replacement (LLV,
LLR) (See: Water Pump/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Solenoid > Component Information > Diagrams
Variable Valve Timing Solenoid: Diagrams
Component Connector End Views
Camshaft Position (CMP) Actuator Solenoid Valve
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications
Fuel Pressure: Specifications
Fuel pressure (Ignition ON, engine OFF).............................................................................................
..............................................345-414 kPa (50-60 psi) fuel pressure should not decrease more than
34 kPa (5 psi) in 1 minute
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications > Page 2110
Fuel Pressure: Service Precautions
Relieving Fuel Pressure Warning
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications > Page 2111
Fuel Pressure: Testing and Inspection
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category.
Circuit/System Description
The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when
the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for
2 seconds unless the engine is in Crank or Run. While this voltage is being received, the FPCM
closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump
module in order to maintain the desired fuel rail pressure.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel
pump module, eliminating the need for a return pipe from the engine. A returnless fuel system
reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the
fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.
The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump
module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and
the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of the
flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump
located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel
pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the
correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow
check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed
pipe and the fuel rail in order to prevent long cranking times.
Electrical Information Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning)for scan
tool information Special Tools
* CH 48027 - Fuel Pressure Gage
* J 37287 - Fuel Line Shut-Off Adapters
Circuit/System Verification
Note: *
Inspect the fuel system for damage or external leaks before proceeding.
* Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
1. Ignition OFF, all accessories OFF, install the CH 48027 - Gage. Refer to Fuel Pressure Gage
Installation and Removal (See: Fuel Filter/Fuel
Pressure Release/Service and Repair/Fuel Pressure Gage Installation and Removal).
2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is
between 345-414 kPa (50-60 psi) and remains steady
for 5 minutes.
Circuit/System Testing
Note: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure
gage while the fuel pump is operating. Verify the
fuel pressure is between 345-414 kPa (50-60 psi).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications > Page 2112
‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel
pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the
items listed below. If all items test
normal, replace the fuel pump.
* Restricted fuel feed pipe
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
Note: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump
stops operating, the fuel pressure should stabilize and remain constant.
2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
‹› If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See:
Fuel Filter/Fuel Pressure Release/Service and
Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)).
2. Install the J 37287 - Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the
valve on the J 37287 - Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a
scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 Shut-Off Adapters. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1
minute.
‹› If the fuel pressure drops, locate and replace the leaking fuel injector.
7. If the fuel system test normal, replace the fuel pump.
3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
‹› If the fuel pressure decreases more than the specified value, replace the fuel pump.
4. Operate the vehicle within the Conditions of the customer's concern while monitoring the fuel
pressure with the CH 48027 - Gage. The fuel
pressure should not drop off during acceleration, cruise or hard cornering.
‹› If the fuel pressure drops off, test, inspect and repair the items listed below. If all items test
normal, replace the fuel sender.
* Restricted fuel feed pipe
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Powertrain
Management/Computers and Control Systems/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls).
Repair Instructions
Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Verification Tests and Procedures) after completing the diagnostic procedure.
* Fuel Hose/Pipes Replacement - Chassis (See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Return Line/Service and Repair)
* Fuel Injector Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel
Injector/Service and Repair/Removal and Replacement)
* Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Pump/Service and Repair)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Resonator Outlet Duct Replacement
Removal Procedure
1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement
(See: Intake Manifold/Service and Repair). 2. Remove the positive crankcase ventilation (PCV) line
(1) from the air cleaner outlet duct.
3. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2117
4. Loosen the air cleaner outlet duct clamp (1) at the throttle body. 5. Grasp the air cleaner outlet
duct near the ball stud and firmly pull up in order to disengage the duct from the ball stud. 6.
Remove the air cleaner outlet duct (2) from the throttle body and the air cleaner housing.
Installation Procedure
1. Install the air cleaner outlet duct (2) to the throttle body and the air cleaner housing. 2. Ensure
that the air cleaner outlet duct tab rests over the ball stud, press down on the duct tab in order to
engage the duct to the ball stud.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the air cleaner outlet duct clamp (1) at the throttle body.
Tighten the clamp to 3.5 Nm (31 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2118
4. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing.
Tighten the clamp to 3.5 Nm (31 lb in).
5. Install the PCV line (1) to the air cleaner outlet duct. 6. Install the intake manifold cover. Refer to
Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Air Cleaner Fresh Air Duct/Hose/Service and
Repair).
2. Release the air cleaner upper housing retainer clips (1).
3. Open the air cleaner upper housing (1). 4. Remove the air filter element (2) from the lower air
cleaner housing. 5. Inspect the air cleaner assembly for debris or damage and repair as necessary.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2122
1. Install the air filter element (2) to the lower air cleaner housing. 2. Close the air cleaner upper
housing (1).
3. Latch the air cleaner upper housing retainer clips (1). 4. Install the air cleaner outlet duct. Refer
to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service
and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning
(See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID).
2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine
cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail
service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten
the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) >
Page 2128
Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel
Pressure Relief (With CH 48027))Fuel Pressure
Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)).
2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or
diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's
directions.
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) >
Page 2129
1. Relieve the fuel system pressure, if required. Perform the following steps:
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from
the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the
fuel rail service port cap. 6. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) >
Page 2130
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH-48027)
Special Tools
CH-48027 - Digital Pressure Gage
Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery
and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID).
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) >
Page 2131
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT
necessary to proceed with the following steps.
12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4)
from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and
place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the
engine cover, if required. 17. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order: Specifications
Ignition System Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Ignition Cable > Component Information > Testing and Inspection
Ignition Cable: Testing and Inspection
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to
accurately identify conditions that may affect engine operation. Inspect for the following conditions:
1. Correct routing of the spark plug wires - Incorrect routing may cause cross-firing. 2. Any signs of
cracks or splits in the wires. 3. Inspect each boot for the following conditions:
* Tearing
* Piercing
* Arcing
* Carbon tracking
* Corroded terminal
If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace
the wire and the component connected to the wire.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Ignition Cable > Component Information > Testing and Inspection > Page 2138
Ignition Cable: Service and Repair
Spark Plug Wire Replacement
Removal Procedure
1. Remove the spark plug wire from the spark plug.
* Twist each spark plug 1/2 turn.
* Pull only on the boot in order to remove the wire from each spark plug.
2. Remove the spark plug wire from the ignition coil.
* Twist each spark plug boot 1/2 turn.
* Pull only on the boot in order to remove the wires from the ignition coil.
Installation Procedure
1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3.
Inspect the wires for proper installation:
* Push sideways on each boot in order to inspect the seating.
* Reinstall any loose boot.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A >
Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306
Spark Plug: Customer Interest Ignition System - Runs Rough MIL/ON DTC P0300/P0306
TECHNICAL
Bulletin No.: 09-06-04-025A
Date: December 20, 2010
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs
Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition
Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille)
Models:
2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER
H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to
GWM/IMH
Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification
section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion
System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) is illuminated.
Some customers may also comment that the engine runs rough.
The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as
current or in history, depending on which engine the vehicle is equipped with.
Upon further examination, the technician may observe evidence of water intrusion into the spark
plug recess area.
Cause
This condition may be caused by an engine being exposed to a large quantity of water, which may
result in some of the water seeping down past the vented threads of an ignition coil bolt, then
flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole,
and collecting in the spark plug recess area.
Correction
Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If
evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the
appropriate DTC procedures in SI.
1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the
affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner
Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical
connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove
the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil
Replacement in SI.
Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply
Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads.
5. Inspect for water intrusion in the spark plug recess areas.
Warning
Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
6. If any water is present, then remove the water from the spark plug recess areas with low
pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug
Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed
into the cylinder head. Refer to Spark Plug Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A >
Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2147
9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as
indicated in the illustration, and apply it to the
ignition coil bolt threads also.
10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition
Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition
coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet
duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a
scan tool.
Hood Grille Modification for HUMMER H3 Vehicles Only
Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall
#10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall
#10088A has been performed on the vehicle, DO NOT perform the following hood grille
modification.
1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille
Replacement (H3T) in SI.
2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention
clip (1) opening in the vehicle hood (all 4
sides of the rectangular slot).
3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly
against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement
(H3T) in SI.
5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme
water pressure should not be directly applied to the
edges of the hood air grille.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A >
Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2148
from other sources.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: >
09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306
Spark Plug: All Technical Service Bulletins Ignition System - Runs Rough MIL/ON DTC
P0300/P0306
TECHNICAL
Bulletin No.: 09-06-04-025A
Date: December 20, 2010
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs
Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition
Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille)
Models:
2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER
H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to
GWM/IMH
Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification
section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion
System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) is illuminated.
Some customers may also comment that the engine runs rough.
The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as
current or in history, depending on which engine the vehicle is equipped with.
Upon further examination, the technician may observe evidence of water intrusion into the spark
plug recess area.
Cause
This condition may be caused by an engine being exposed to a large quantity of water, which may
result in some of the water seeping down past the vented threads of an ignition coil bolt, then
flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole,
and collecting in the spark plug recess area.
Correction
Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If
evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the
appropriate DTC procedures in SI.
1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the
affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner
Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical
connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove
the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil
Replacement in SI.
Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply
Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads.
5. Inspect for water intrusion in the spark plug recess areas.
Warning
Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
6. If any water is present, then remove the water from the spark plug recess areas with low
pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug
Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed
into the cylinder head. Refer to Spark Plug Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: >
09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2154
9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as
indicated in the illustration, and apply it to the
ignition coil bolt threads also.
10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition
Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition
coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet
duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a
scan tool.
Hood Grille Modification for HUMMER H3 Vehicles Only
Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall
#10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall
#10088A has been performed on the vehicle, DO NOT perform the following hood grille
modification.
1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille
Replacement (H3T) in SI.
2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention
clip (1) opening in the vehicle hood (all 4
sides of the rectangular slot).
3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly
against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement
(H3T) in SI.
5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme
water pressure should not be directly applied to the
edges of the hood air grille.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: >
09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2155
from other sources.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Page 2156
Spark Plug: Specifications
Ignition System Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Page 2157
Spark Plug: Application and ID
Ignition System Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Page 2158
Spark Plug: Testing and Inspection
Spark Plug Inspection
* Verify that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications ( See: Powertrain Management/Ignition
System/Specifications) for the correct spark plug.
* Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling - Colder plug
- Pre-ignition causing spark plug and/or engine damage - Hotter plug
* Inspect the terminal post (1) for damage.
- Inspect for a bent or broken terminal post (1)
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post should not
move.
* Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical
charge traveling across the insulator between the terminal post (1) and ground. Inspect for the
following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess are of the cylinder head for moisture, such as oil, coolant, or water.
A spark plug boot that is saturated will cause arcing to ground.
* Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack
instead of the electrodes (3,4).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Page 2159
* Inspect for evidence of improper arcing.
- Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition
System Specifications (See: Powertrain Management/Ignition System/Specifications). An
excessively wide electrode gap can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Powertrain
Management/Ignition System/Specifications). Insufficient torque can prevent correct spark plug
operation. An over torqued spark plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
* A rattling sound indicates internal damage.
* A looses center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3,4). Deposits on the electrodes (3,4) reduce or eliminates the
gap.
- Inspect for worn or missing platinum pads on the electrodes (3,4), if equipped.
- Inspect for excessive fouling.
* Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during installation.
Visual Inspection
* Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are
normal combustion by-products from fuels with additives.
* Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions:
- Rich fuel mixtures
* Leaking fuel injectors
* Excessive fuel pressure
* Restricted air filter element
* Incorrect combustion
- Reduced ignition system voltage output
* Weak ignition coils
* Worn ignition wires
* Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that
normal combustion deposits may not burn off.
* Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white
coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity
unless they form into a glazing over the electrode.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Page 2160
Spark Plug: Service and Repair
Spark Plug Replacement
Removal Procedure
1. Remove the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition
Cable/Service and Repair). 2. Loosen the spark plug 1-2 turns. 3. Brush or using compressed air,
blow away any dirt from around the spark plug. 4. Remove the spark plug.
If removing more than one plug, place each plug in a tray marked with the corresponding cylinder
number.
Installation Procedure
1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as
needed. Refer to Ignition System Specifications (See: Powertrain Management/Ignition
System/Specifications).
3. Hand start the spark plug in the corresponding cylinder.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Tighten the spark plug.
Tighten the plug to 20 Nm (15 lb ft).
5. Install the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition Cable/Service
and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
COMPRESSION CHECK
If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the
combustion chamber through the spark plug hole. Measure the compression again and record the
reading. The minimum compression in any 1 cylinder should not be less than 70 percent of the
highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest
pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other
cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 2164
Compression Check: Testing and Inspection
Engine Compression Test
1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable
the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6.
Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression
gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the
compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject
approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark
plug
hole. Measure the compression again and record the reading.
10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690 kPa
(100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest
allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x
70% = 105).
* Normal - Compression builds up quickly and evenly to the specified compression for each
cylinder.
* Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the
following strokes, but does not reach normal. Compression improves considerably when you add
oil.
* Valves Leaking - Compression is low on the first stroke. Compression usually does not build up
on the following strokes. Compression does not improve much when you add oil.
* If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders
does not increase the compression, the cause may be a head gasket leaking between the
cylinders.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications
Water Pump: Specifications
WATER PUMP
Water Pump Bolts First Pass................................................................................................................
.......................................................................................15 Nm (11 lb ft) Final Pass............................
..............................................................................................................................................................
............30 Nm (22 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Page 2168
Water Pump: Service and Repair
Water Pump Replacement (With LH8) (5.3L)
Removal Procedure
1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Tune-up and Engine Performance Checks/Air
Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair).
2. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling
System/Service and Repair)Cooling System
Draining and Filling (Vac N Fill) (See: Cooling System/Service and Repair).
3. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 4. Remove
the radiator vent inlet hose (2) from the coolant air bleed pipe fitting.
5. Reposition the radiator inlet hose clamp (3) at the water pump. 6. Remove the radiator inlet hose
from the water pump. 7. Reposition the radiator inlet hose and vent inlet hose out of the way.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Page 2169
8. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Drive Belt Replacement - Accessory).
9. Reposition the radiator outlet hose clamp (1) at the water pump.
10. Remove the radiator outlet hose (2) from the water pump. 11. Reposition the outlet hose out of
the way.
12. Reposition the radiator surge tank outlet hose clamp (1) at the water pump (2). 13. Remove the
radiator surge tank outlet hose (3) from the water pump. 14. Reposition the outlet hose out of the
way. 15. Reposition the heater inlet hose clamp (4) at the water pump. 16. Remove the heater inlet
hose (5) from the water pump. 17. Reposition the inlet hose out of the way.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Page 2170
18. Remove the water pump bolts (301). 19. Remove the water pump (300) and gaskets (309).
Discard the gaskets.
Installation Procedure
Caution: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed.
The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the
passages of the cooling system or the engine components. Restricted coolant flow may cause
engine overheating and/or damage to the cooling system or the engine components/assembly.
Note: All gaskets surfaces are to be free of oil or other foreign material during assembly.
1. Position the water pump (300) and NEW gaskets (306) to the engine block.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the water pump bolts (301).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Page 2171
1. Tighten the bolts a first pass to 15 Nm (11 lb ft). 2. Tighten the bolts a final pass to 30 Nm (22 lb
ft).
3. Position and install the heater inlet hose (5) to the water pump. 4. Position the heater inlet hose
clamp (4) at the water pump. 5. Position and install the radiator surge tank outlet hose (3) to the
water pump. 6. Position the radiator surge tank outlet hose clamp (1) at the water pump (2).
7. Position and install the radiator outlet hose (2) to the water pump. 8. Position the radiator outlet
hose clamp (1) at the water pump. 9. Install the accessory drive belt. Refer to Drive Belt
Replacement - Accessory (See: Drive Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Drive Belt Replacement - Accessory).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Page 2172
10. Position the radiator inlet hose and vent inlet hose to the correct position. 11. Install the radiator
inlet hose to the water pump. 12. Position the radiator inlet hose clamp (3) at the water pump.
13. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 14. Position the
radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 15. Fill the cooling system.
Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and
Repair)Cooling System
Draining and Filling (Vac N Fill) (See: Cooling System/Service and Repair).
16. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Tune-up and Engine Performance Checks/Air
Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Cooling System ...................................................................................................................................
.............................................. 13.7 quarts (13.0 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications > Page 2178
Coolant: Fluid Type Specifications
ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant.
This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km),
whichever occurs first, if you add only DEX-COOL extended life coolant.
A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: Give freezing protection
down to -34°F (-37°C). Give boiling protection up to 265°F (129°C). Protect against rust and
corrosion. Help keep the proper engine temperature. Let the warning lights and gages work as they
should.
NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or
radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles
(50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your
warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle.
WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant
which won't damage aluminum parts. If you use this coolant mixture, you don't need to add
anything else.
CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some
other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant
warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your
engine could get too hot but you would not get the overheat warning. Your engine could catch fire
and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL
coolant.
NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly
damaged. The repair cost would not be covered by your warranty. Too much water in the mixture
can freeze and crack the engine, radiator, heater core and other parts.
If you have to add coolant more than four times a year, check your cooling system.
NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle
could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair
Coolant Line/Hose: Service and Repair
Engine Coolant Air Bleed Pipe Replacement (With LH8) (5.3L)
Removal Procedure
1. If replacing the rear coolant air bleed covers, remove the intake manifold. Refer to Intake
Manifold Replacement (See: Engine/Intake
Manifold/Service and Repair). Otherwise proceed to the next step.
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Engine/Tune-up and Engine Performance
Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair).
3. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair)Cooling System Draining and
Filling (Vac N Fill) (See: Service and Repair).
4. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 5. Remove
the radiator vent inlet hose (2) from the coolant air bleed pipe fitting.
6. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Page 2182
7. Remove the coolant air bleed pipe (307) and seals (308).
8. Remove the coolant air bleed cover bolts (312), if required. 9. Remove the coolant air bleed
covers (313) and seals (308), if required.
10. Remove the seals (308) from the coolant air bleed pipe and/or covers. 11. Discard the seals.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Page 2183
Note: Position the O-ring seal (308) onto the nipple portion of the pipe.
1. Install the seals onto the coolant air bleed pipe and/or covers.
2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the coolant air bleed pipe bolts (309) and tighten to 12 Nm (106 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Page 2184
4. Install the coolant air bleed covers (313) and seals (308), if required. 5. Install the coolant air
bleed cover bolts (312), if required and tighten to 12 Nm (106 lb in).
6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 7. Position the radiator
vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 8. Install the air cleaner outlet duct.
Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine
Performance
Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair).
9. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair)Cooling System Draining and Filling
(Vac N Fill) (See: Service and Repair).
10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to Intake
Manifold Replacement (See: Engine/Intake
Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component
Information > Service and Repair > Coolant Recovery Reservoir Replacement
Coolant Reservoir: Service and Repair Coolant Recovery Reservoir Replacement
Coolant Recovery Reservoir Replacement
Removal Procedure
1. Partially drain the coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair)Cooling System Draining and
Filling (Vac N Fill) (See: Service and Repair).
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See:
Engine/Tune-up and Engine Performance Checks/Air
Cleaner Housing/Service and Repair) or Air Cleaner Assembly Replacement (See: Engine/Tune-up
and Engine Performance Checks/Air Cleaner Housing/Service and Repair).
3. Remove the coolant overflow hose (6) from the coolant recovery reservoir (5). 4. Remove the
bolt (4) securing the coolant recovery reservoir (5) to the coolant recovery reservoir bracket. 5.
Remove the radiator vent hose from the coolant recovery reservoir. 6. Remove the bolt securing
the coolant recovery reservoir (5) to the front wheel house panel. 7. Remove the coolant recovery
reservoir.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component
Information > Service and Repair > Coolant Recovery Reservoir Replacement > Page 2189
1. Install the coolant recovery reservoir.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the retaining bolt to the front wheelhouse panel and tighten the bolt to 12 Nm (106 lb in).
3. Install the radiator vent hose to the coolant recovery reservoir. 4. Install the bolt (4) securing the
coolant recovery reservoir (5) to the coolant recovery reservoir bracket.
Tighten the nut to 10 Nm (88 lb in).
5. Install the overflow hose (6) to the coolant recovery reservoir (5). 6. Install the air cleaner
assembly. Refer to Air Cleaner Assembly Replacement (See: Engine/Tune-up and Engine
Performance Checks/Air Cleaner
Housing/Service and Repair) or Air Cleaner Assembly Replacement (See: Engine/Tune-up and
Engine Performance Checks/Air Cleaner Housing/Service and Repair).
7. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair)Cooling System Draining and Filling
(Vac N Fill) (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component
Information > Service and Repair > Coolant Recovery Reservoir Replacement > Page 2190
Coolant Reservoir: Service and Repair Radiator Vent Inlet Hose Replacement
Radiator Vent Inlet Hose Replacement
Removal Procedure
1. Partially drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See:
Service and Repair)Cooling System Draining
and Filling (Vac N Fill) (See: Service and Repair).
2. Remove the vent inlet hose from the radiator. 3. Remove the retaining clips from the radiator
vent inlet hose. 4. Remove the radiator vent inlet hose (3) from the coolant recovery reservoir (2).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component
Information > Service and Repair > Coolant Recovery Reservoir Replacement > Page 2191
1. Install the radiator vent inlet hose (3) to the coolant recovery reservoir (2). 2. Install the retaining
clips to the radiator vent inlet hose. 3. Install the radiator vent inlet hose to the radiator. 4. Fill the
cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and
Repair)Cooling System Draining and Filling
(Vac N Fill) (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Testing and Inspection
Fan Clutch: Testing and Inspection
Fan Clutch Diagnosis
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Testing and Inspection > Page 2196
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Testing and Inspection > Page 2197
Fan Clutch: Service and Repair
Fan Clutch Replacement
Removal Procedure
1. Remove the cooling fan. Refer to Fan Replacement (LH8) (See: Service and Repair)Fan
Replacement (LLV, LLR) (See: Service and Repair).
2. Remove the bolts retaining the fan blade to the fan clutch. 3. Separate the fan blade from the fan
clutch.
Installation Procedure
1. Assemble the fan to the fan clutch.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the 4 bolts to the fan blade and tighten to 27 Nm (20 lb ft). 3. Install the cooling fan. Refer
to Fan Replacement (LH8) (See: Service and Repair)Fan Replacement (LLV, LLR) (See: Service
and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2202
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2203
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining
and Filling (Static Fill) (See: Service and Repair
)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant
temperature (ECT) sensor.
3. Remove the ECT sensor (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2204
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent. 2. Install the ECT sensor (1).
Tighten the sensor to 20 Nm (15 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the
cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair)Cooling System
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2205
Draining and Filling (Vac N Fill) (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Service and Repair
Fan Shroud: Service and Repair
Engine Coolant Fan Shroud Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair
Heater Core: Service and Repair
Heater Core Replacement
Removal Procedure
1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See:
Heating and Air Conditioning/Housing Assembly
HVAC/Service and Repair).
2. Remove the heater core pipes clamp screw (3). 3. Remove the heater core pipes clamp (2). 4.
Remove the heater core clamp screws. 5. Remove the heater core clamp (2). 6. Remove the
heater core from the HVAC module.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Page 2212
1. Install the heater core to the HVAC module. 2. Install the heater core clamp (2).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the heater core clamp screws. Tighten the screws to 1.9 Nm (17 lb in). 4. Install the heater
core pipes clamp (2). 5. Install the heater core pipes clamp screw (3). Tighten the screw to 20 Nm
(15 lb ft). 6. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement
(See: Heating and Air Conditioning/Housing Assembly
HVAC/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement
Heater Hose: Service and Repair Heater Inlet Hose Replacement
Heater Inlet Hose Replacement
Tools Required
* J 38185 Hose Clamp Pliers
* J 43181 Heater Line Quick Connect Release Tool
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair)Cooling System Draining and
Filling (Vac N Fill) (See: Service and Repair).
2. Using the J 43181 , release the inlet heater hose quick connect (1) from the heater core inlet. 3.
Position the inlet heater hose clamp (4) at the engine block using J 38185 . 4. Remove the heater
inlet hose (3) from the inlet hose fitting (6) at the engine block. 5. Remove the heater inlet hose (3).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement > Page 2217
1. Apply coolant to the end of the heater inlet hose (5).
Important: When installing a new heater inlet hose, place the clamps on the hose before installing
the hose to the inlet hose fitting at the engine block.
2. Install the heater inlet hose (3) to the inlet hose fitting (6) at the engine block. 3. Position the inlet
heater hose clamp (4) at the engine block using J 38185 . 4. Install the heater inlet hose (3) to the
heater core inlet. 5. Press the quick connect (1) onto the heater core inlet until fully seated. 6. Fill
the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair)Cooling System Draining and
Filling (Vac N Fill) (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement > Page 2218
Heater Hose: Service and Repair Heater Outlet Hose Replacement
Heater Outlet Hose Replacement
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair)Cooling System Draining and
Filling (Vac N Fill) (See: Service and Repair).
2. Remove the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (4WD 5.3L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 5.3L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
3. Remove the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and
Charging/Charging System/Alternator/Service and
Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and
Charging/Charging System/Alternator/Service and Repair/Generator Replacement).
4. Using the J 38185 disconnect the outlet hose from the heater core outlet tube. 5. Remove the
heater outlet hose from the heater core.
6. Position the outlet heater hose clamp (6) at the water pump using J 38185 . 7. Remove the
heater outlet hose (7) from the outlet hose fitting. 8. Remove the heater outlet hose.
Installation Procedure
1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3.
Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185 . 4. Install the
heater outlet hose to the heater core. 5. Position the outlet heater hose clamp at the heater core
using J 38185 . 6. Install the transmission. Refer to Transmission Replacement (4WD 2.9L and
3.7L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (4WD 5.3L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 5.3L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement > Page 2219
2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and
Repair/Removal and Replacement).
7. Install the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and
Charging/Charging System/Alternator/Service and
Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and
Charging/Charging System/Alternator/Service and Repair/Generator Replacement).
8. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair)Cooling System Draining and Filling
(Vac N Fill) (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement > Page 2220
Heater Hose: Service and Repair Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe
Replacement
Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement > Page 2221
Heater Hose: Service and Repair Heater Inlet Pipe Replacement
Heater Inlet Pipe Replacement
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See:
Service and Repair)Cooling System Draining
and Filling (Vac N Fill) (See: Service and Repair).
2. Using the J 38185 , reposition the heater hose outlet clamp from the heater pipe inlet. 3.
Remove the heater hose outlet from the heater pipe inlet. 4. Remove the exhaust heat shield.
Refer to Exhaust Manifold Heat Shield Replacement (LLV) ()Exhaust Manifold Heat Shield
Replacement (LLR)
().
5. Remove the heater inlet pipe bolt. 6. Remove the heater inlet pipe.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement > Page 2222
1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet
hose fitting threads.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the heater outlet hose fitting. Tighten the heater outlet hose fitting to 45 Nm (33 lb ft). 3.
Install the heater hose outlet to the heater pipe inlet. 4. Using the J 38185 , reposition the heater
hose outlet clamp to the heater pipe inlet. 5. Install the exhaust heat shield. Refer to Exhaust
Manifold Heat Shield Replacement (LLV) ()Exhaust Manifold Heat Shield Replacement (LLR)
().
6. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (Vac N Fill) (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement > Page 2223
Heater Hose: Service and Repair Heater Outlet Pipe Replacement
Heater Outlet Pipe Replacement
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See:
Service and Repair)Cooling System Draining
and Filling (Vac N Fill) (See: Service and Repair).
2. Using the J 38185 , reposition the heater hose inlet clamp from the heater pipe outlet. 3.
Remove the heater hose inlet from the heater pipe outlet.
4. Loosen the heater pipe outlet. 5. Remove the heater pipe outlet.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement > Page 2224
1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet
hose fitting threads.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the heater outlet hose fitting. Tighten the heater outlet hose fitting to 45 Nm (33 lb ft). 3.
Install the heater hose inlet to the heater pipe outlet. 4. Using the J 38185 , reposition the heater
hose inlet clamp to the heater pipe outlet. 5. Fill the engine cooling system. Refer to Cooling
System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and
Filling (Vac N Fill) (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Service and Repair
Radiator: Service and Repair
Radiator Replacement
Special Tools
J 38185 Hose Clamp Pliers
Removal Procedure
1. Remove the fan shroud. Refer to Engine Coolant Fan Shroud Replacement (LLV, LLR) (See:
Fan Shroud/Service and Repair)Engine Coolant
Fan Shroud Replacement (LH8) (See: Fan Shroud/Service and Repair).
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair).
3. Using J 38185 reposition the radiator outlet hose clamp (2) from the radiator. 4. Remove the
outlet radiator hose (1) from the radiator.
5. Remove the transmission cooler lines from the radiator. Refer to Transmission Fluid Cooler
Hose/Pipe Quick-Connect Fitting Disconnection and
Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid
Line/Hose/Service and Repair).
6. Lower the vehicle. 7. Remove the radiator vent inlet hose from the radiator. 8. Remove the
radiator mounting bracket bolt. 9. Remove the radiator mount.
10. Remove the grill. 11. Remove the condenser mounting bolts. 12. Separate the condenser from
the radiator. 13. Remove the radiator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Service and Repair > Page 2228
Installation Procedure
1. Install the radiator. 2. Install the condenser to the radiator.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the bolts retaining the condenser to the radiator and tighten to 28 Nm (21 lb ft). 4. Install
the grille. 5. Install the radiator mount bracket. 6. Install the radiator mounting bracket bolt and
tighten to 28 Nm (21 lb ft). 7. Raise the vehicle.
8. Install the radiator outlet hose (1) to the radiator. 9. Using J 38185 reposition the radiator outlet
hose clamp (2) to the radiator.
10. Connect the transmission cooler lines to the radiator. Refer to Transmission Fluid Cooler
Hose/Pipe Quick-Connect Fitting Disconnection and
Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid
Line/Hose/Service and Repair).
11. Lower the vehicle. 12. Install the radiator vent inlet hose to the radiator. 13. Install the fan
shroud. Refer to Engine Coolant Fan Shroud Replacement (LLV, LLR) (See: Fan Shroud/Service
and Repair)Engine Coolant Fan
Shroud Replacement (LH8) (See: Fan Shroud/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Testing and Inspection
Radiator Cap: Testing and Inspection
Pressure Cap Testing
Special Tools
J 24460-01 Cooling System Pressure Tester
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam under pressure if radiator cap or surge
tank cap is removed while the engine and radiator are still hot.
1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water.
3. Use the J 24460-01 in order to test the pressure cap. 4. Test the pressure cap for the following
conditions:
* Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap.
* Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss.
5. Replace the pressure cap under the following conditions:
* The pressure cap does not release pressure which exceeds the rated pressure of the cap.
* The pressure cap does not hold the rated pressure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information
> Service and Repair > Radiator Inlet Hose Replacement
Radiator Hose: Service and Repair Radiator Inlet Hose Replacement
Radiator Inlet Hose Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information
> Service and Repair > Radiator Inlet Hose Replacement > Page 2236
Radiator Hose: Service and Repair Radiator Outlet Hose Replacement
Radiator Outlet Hose Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 2242
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 2243
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining
and Filling (Static Fill) (See: Service and Repair
)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant
temperature (ECT) sensor.
3. Remove the ECT sensor (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 2244
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent. 2. Install the ECT sensor (1).
Tighten the sensor to 20 Nm (15 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the
cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair)Cooling System
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 2245
Draining and Filling (Vac N Fill) (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling >
Component Information > Specifications
Thermostat: Specifications
Use a tempilstick in order to find the opening and the closing temperatures of the coolant
thermostat.
* J 24731-188 tempilstick melts at 87°C (188°F). The thermostat should begin to open at 90°C
(194°F).
* J 24731-206 tempilstick melts at 97°C (206°F). The thermostat should be fully open at 107°C
(225°F).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling >
Component Information > Specifications > Page 2249
Thermostat: Service and Repair
Engine Coolant Thermostat Replacement (LH8) (5.3L)
Removal Procedure
1. Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement
(With LH8) (See: Thermostat Housing/Service and
Repair).
2. Remove the thermostat.
Installation Procedure
1. Install the thermostat. 2. Install the thermostat housing. Refer to Engine Coolant Thermostat
Housing Replacement (With LH8) (See: Thermostat Housing/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Service and Repair
Thermostat Housing: Service and Repair
Engine Coolant Thermostat Housing Replacement (With LH8) (5.3L)
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair)Cooling System Draining and
Filling (Vac N Fill) (See: Service and Repair).
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Engine/Tune-up and Engine Performance
Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair).
3. Reposition the radiator outlet hose clamp (1) at the water pump inlet. 4. Remove the radiator
outlet hose (2) from the water pump inlet.
5. Remove the water pump inlet bolts (1). 6. Remove the water pump inlet from the water pump. 7.
Remove and discard the water pump inlet seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Service and Repair > Page 2253
Installation Procedure
1. Install a NEW water pump inlet seal to the water pump inlet. 2. Position the water pump inlet to
the water pump.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the water pump inlet bolts (1).
Tighten the bolts to 15 Nm (11 lb ft).
4. Install the radiator outlet hose (2) to the water pump inlet. 5. Position the radiator outlet hose
clamp (1) at the water pump inlet. 6. Install the air cleaner outlet duct. Refer to Air Cleaner
Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance
Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair).
7. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair)Cooling System Draining and Filling
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Service and Repair > Page 2254
(Vac N Fill) (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications
Water Pump: Specifications
WATER PUMP
Water Pump Bolts First Pass................................................................................................................
.......................................................................................15 Nm (11 lb ft) Final Pass............................
..............................................................................................................................................................
............30 Nm (22 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 2258
Water Pump: Service and Repair
Water Pump Replacement (With LH8) (5.3L)
Removal Procedure
1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Engine/Tune-up and Engine Performance
Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair).
2. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair)Cooling System Draining and
Filling (Vac N Fill) (See: Service and Repair).
3. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 4. Remove
the radiator vent inlet hose (2) from the coolant air bleed pipe fitting.
5. Reposition the radiator inlet hose clamp (3) at the water pump. 6. Remove the radiator inlet hose
from the water pump. 7. Reposition the radiator inlet hose and vent inlet hose out of the way.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 2259
8. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See:
Engine/Drive Belts, Mounts, Brackets and
Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory).
9. Reposition the radiator outlet hose clamp (1) at the water pump.
10. Remove the radiator outlet hose (2) from the water pump. 11. Reposition the outlet hose out of
the way.
12. Reposition the radiator surge tank outlet hose clamp (1) at the water pump (2). 13. Remove the
radiator surge tank outlet hose (3) from the water pump. 14. Reposition the outlet hose out of the
way. 15. Reposition the heater inlet hose clamp (4) at the water pump. 16. Remove the heater inlet
hose (5) from the water pump. 17. Reposition the inlet hose out of the way.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 2260
18. Remove the water pump bolts (301). 19. Remove the water pump (300) and gaskets (309).
Discard the gaskets.
Installation Procedure
Caution: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed.
The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the
passages of the cooling system or the engine components. Restricted coolant flow may cause
engine overheating and/or damage to the cooling system or the engine components/assembly.
Note: All gaskets surfaces are to be free of oil or other foreign material during assembly.
1. Position the water pump (300) and NEW gaskets (306) to the engine block.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the water pump bolts (301).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 2261
1. Tighten the bolts a first pass to 15 Nm (11 lb ft). 2. Tighten the bolts a final pass to 30 Nm (22 lb
ft).
3. Position and install the heater inlet hose (5) to the water pump. 4. Position the heater inlet hose
clamp (4) at the water pump. 5. Position and install the radiator surge tank outlet hose (3) to the
water pump. 6. Position the radiator surge tank outlet hose clamp (1) at the water pump (2).
7. Position and install the radiator outlet hose (2) to the water pump. 8. Position the radiator outlet
hose clamp (1) at the water pump. 9. Install the accessory drive belt. Refer to Drive Belt
Replacement - Accessory (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Drive Belt Replacement - Accessory).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 2262
10. Position the radiator inlet hose and vent inlet hose to the correct position. 11. Install the radiator
inlet hose to the water pump. 12. Position the radiator inlet hose clamp (3) at the water pump.
13. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 14. Position the
radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 15. Fill the cooling system.
Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System
Draining and Filling
(Vac N Fill) (See: Service and Repair).
16. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Engine/Tune-up and Engine Performance
Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield >
Component Information > Service and Repair
Catalyst Shield: Service and Repair
Catalytic Converter Heat Shield Replacement
Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions).
Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician
Safety Information/Protective Goggles and Glove Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Remove the 5 nuts securing the heat shield to the floor panel. 3. Remove the catalytic converter
heat shield from the floor panel.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield >
Component Information > Service and Repair > Page 2268
1. Position the catalytic converter heat shield to the floor panel studs.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the 5 nuts securing the heat shield to the floor panel. Tighten the heat shield nuts to 9 Nm
(80 lb in). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Specifications
Exhaust Manifold: Specifications
EXHAUST MANIFOLD
Exhaust Manifold Bolts First Pass........................................................................................................
...............................................................................................15 Nm (11 lb ft) Final Pass....................
..............................................................................................................................................................
....................20 Nm (15 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side
Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Side
Exhaust Manifold Replacement - Left Side (LH8) (5.3L)
Removal Procedure
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the catalytic converter to exhaust
manifold nuts (2). 3. Lower the vehicle. 4. Remove the upper intake manifold sight shield. Refer to
Upper Intake Manifold Sight Shield Replacement (See: Engine/Intake Manifold/Service
and Repair)
5. Remove the spark plugs. Refer to Spark Plug Replacement (See: Engine/Tune-up and Engine
Performance Checks/Spark Plug/Service and
Repair).
6. Disconnect the ignition coil bracket from the valve rocker arm cover. Refer to Valve Rocker Arm
Cover Replacement - Left Side (See:
Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover
Replacement - Left Side)
7. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement Left Side (LH8) (See: Heat Shield/Service and
Repair/Exhaust Manifold Heat Shield Replacement - Left Side).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 2274
8. Remove the exhaust manifold bolts (1). 9. Remove the exhaust manifold (2) and gasket (3).
Discard the gasket.
Installation Procedure
Note:
* Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed
and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board
Diagnostics (OBD) II system performance.
* The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or
threadlocking material.
Note: Do not apply sealant to the first 3 threads of the bolt.
1. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493, (Canadian P/N 10953488), or
equivalent to the threads of the exhaust
manifold bolts.
2. Ensure that the exhaust seal is still seated on the catalytic converter recess. 3. Install one
exhaust manifold bolt to the exhaust manifold (2) and place the NEW gasket (3) onto the bolt. 4.
Install the exhaust manifold to the catalytic converter flange and position the manifold to the
cylinder head.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 2275
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Install the remaining exhaust manifold bolts (1).
1. Tighten the bolts a first pass to 15 Nm (11 lb ft). Tighten the bolts beginning with the center 2
bolts. Alternate from side-to-side, and work
toward the outside bolts.
2. Tighten the bolts a final pass to 25 Nm (18 lb ft). Tighten the bolts beginning with the center 2
bolts. Alternate from side-to-side, and work
toward the outside bolts.
6. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the
left cylinder head. 7. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat
Shield Replacement - Left Side (LH8) (See: Heat Shield/Service and
Repair/Exhaust Manifold Heat Shield Replacement - Left Side).
8. Install the ignition coil bracket to the valve rocker arm cover. refer to Valve Rocker Arm Cover
Replacement - Left Side (See: Engine/Cylinder
Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left
Side)
9. Install the spark plugs. Refer to Spark Plug Replacement (See: Engine/Tune-up and Engine
Performance Checks/Spark Plug/Service and Repair).
10. Install upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Engine/Intake Manifold/Service and
Repair)
11. Raise the vehicle.
12. Install the catalytic converter to exhaust manifold nuts (2).
Tighten the nuts to 50 Nm (37 lb ft).
13. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 2276
Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Side
Exhaust Manifold Replacement - Right Side (LH8) (5.3L)
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the catalytic converter to exhaust
manifold nuts (2). 3. Lower the vehicle. 4. Remove the spark plugs. Refer to Spark Plug
Replacement (See: Engine/Tune-up and Engine Performance Checks/Spark Plug/Service and
Repair).
5. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement Right Side (LH8) (See: Heat Shield/Service and
Repair/Exhaust Manifold Heat Shield Replacement - Right Side).
6. Remove the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement
(See: Engine/Engine Lubrication/Engine Oil Dip
Stick - Dip Stick Tube/Service and Repair).
7. Remove the exhaust manifold bolts (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 2277
8. Remove the exhaust manifold (2) and gasket (1). Discard the gasket.
Installation Procedure
Note:
* Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed
and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board
Diagnostics (OBD) II system performance.
* The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or
threadlocking material.
Note: Do not apply sealant to the first 3 threads of the bolt.
1. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493, (Canadian P/N 10953488), or
equivalent to the threads of the exhaust
manifold bolts.
2. Ensure that the exhaust seal is still seated on the catalytic converter recess. 3. Install one
exhaust manifold bolt to the exhaust manifold (2) and place the NEW gasket (1) onto the bolt. 4.
Install the exhaust manifold to the catalytic converter flange and position the manifold to the
cylinder head. 5. Install the oil level indicator and tube. Refer to Oil Level Indicator and Tube
Replacement (See: Engine/Engine Lubrication/Engine Oil Dip Stick
- Dip Stick Tube/Service and Repair).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the remaining exhaust manifold bolts (3).
1. Tighten the bolts a first pass to 15 Nm (11 lb ft). Tighten the bolts beginning with the center 2
bolts. Alternate from side-to-side, and work
toward the outside bolts.
2. Tighten the bolts a final pass to 25 Nm (18 lb ft). Tighten the bolts beginning with the center 2
bolts. Alternate from side-to-side, and work
toward the outside bolts.
7. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of
the right cylinder head. 8. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat
Shield Replacement - Left Side (LH8) (See: Heat Shield/Service and
Repair/Exhaust Manifold Heat Shield Replacement - Left Side).
9. Install the spark plugs. Refer to Spark Plug Replacement (See: Engine/Tune-up and Engine
Performance Checks/Spark Plug/Service and Repair).
10. Raise the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 2278
11. Install the catalytic converter to exhaust manifold nuts.
Tighten the nuts to 50 Nm (37 lb ft).
12. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger >
Component Information > Service and Repair
Exhaust Pipe/Muffler Hanger: Service and Repair
Exhaust System Insulator, Hanger, Bracket Replacement
Service the exhaust hangers individually in order to retain the support of the exhaust system.
Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions).
Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician
Safety Information/Protective Goggles and Glove Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
Note: Do not use oil base lubricants.
2. Apply a soapy solution to the following in order to ease the removal of the hanger (1):
* The frame support bracket rod (2)
* The exhaust pipe hanger rod (3)
3. Pry the exhaust pipe hanger (1) free from the following:
* The frame support bracket rod (2)
* The exhaust pipe hanger rod (3)
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger >
Component Information > Service and Repair > Page 2282
Note: Do not use oil base lubricants.
1. Apply a soapy solution to the following in order to ease the installation of the hanger (1):
* The frame support bracket rod (2)
* The inner diameter of the exhaust pipe hanger (1)
* The exhaust pipe hanger rod (3)
2. Press the exhaust pipe hanger (1) over the following:
* The frame support bracket rod (2)
* The exhaust pipe hanger rod (3)
3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side
Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Right Side
Exhaust Manifold Heat Shield Replacement - Right Side (LH8) (5.3L)
Removal Procedure
1. Open the hood. 2. Remove the exhaust manifold heat shield bolts (1) and shield (2).
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Position the exhaust manifold heat shield (2) to the manifold and install the bolts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2287
Tighten the bolts to 9 Nm (80 lb in).
2. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2288
Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Left Side
Exhaust Manifold Heat Shield Replacement - Left Side (LH8) (5.3L)
Removal Procedure
1. Open the hood. 2. Remove the exhaust manifold heat shield bolts (1) and shield (2).
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Position the exhaust manifold heat shield (2) to the manifold and install the bolts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2289
Tighten the bolts to 9 Nm (80 lb in).
2. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2290
Heat Shield: Service and Repair Exhaust Muffler Heat Shield Replacement
Exhaust Muffler Heat Shield Replacement
Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions).
Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician
Safety Information/Protective Goggles and Glove Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Remove the 3 nuts securing the heat shield to the floor panel. 3. Remove the exhaust muffler
heat shield from the floor panel.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2291
1. Position the exhaust muffler heat shield to the floor panel studs.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the 3 nuts securing the heat shield to the floor panel. Tighten the heat shield nuts to 9 Nm
(80 lb in). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2292
Heat Shield: Service and Repair Exhaust Pipe Heat Shield Replacement
Exhaust Pipe Heat Shield Replacement
Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions).
Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician
Safety Information/Protective Goggles and Glove Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Remove the 4 nuts securing the heat shield to the floor panel. 3. Remove the exhaust pipe heat
shield from the floor panel.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2293
1. Position the exhaust pipe heat shield to the floor panel studs.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the 4 nuts securing the heat shield to the floor panel. Tighten the heat shield nuts to 9 Nm
(80 lb in). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Service and Repair
Muffler: Service and Repair
Exhaust Muffler Replacement (LH8) (5.3L)
Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions).
Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician
Safety Information/Protective Goggles and Glove Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
Note: Use care not to over extend the rear brake hose.
2. Complete the following in order to gain clearance to remove the muffler:
1. Remove the lower shock absorber nuts (9) and bolts (8). 2. Remove the right rear leaf spring nut
(2) and bolt (1). 3. Wedge a block of wood (5) between the frame (4) and the rear axle (6).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Service and Repair > Page 2297
3. Remove the catalytic converter nuts (1). 4. Loosen the front exhaust muffler pipe at the catalytic
converter clamp (2). 5. Separate the front exhaust muffler pipe hanger from the insulator. 6.
Separate the front exhaust muffler pipe from the catalytic converters.
Note: Do not use oil base lubricants.
7. Apply a soapy solution to the exhaust pipe hanger rods (3) in order to ease the removal of the
exhaust hangers (1). 8. Pry the exhaust hangers (1) free from the exhaust pipe hanger rods (3). 9.
Complete the following in order to remove the muffler from the vehicle:
Note: It may be necessary to rotate the Muffler in order to gain clearance.
1. Slide the muffler rearward from the catalytic converter. 2. Carefully remove the muffler rearward
from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Service and Repair > Page 2298
Caution: Do not over-flex or damage the flex joint when moving the flex joint from the normal
mounting position.
1. Complete the following in order to install the muffler to the vehicle:
Note: It may be necessary to rotate the Muffler in order to gain clearance.
1. Carefully insert the muffler over the rear axle until the flange is near the catalytic converter. 2.
Slide the muffler forward into position, aligning the studs with the rear of the catalytic converter.
Note: Do not use oil base lubricants.
2. Apply a soapy solution to the following in order to ease the installation of the hangers (1):
* The inner diameter of the exhaust pipe hanger (1)
* The exhaust pipe hanger rod (3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Service and Repair > Page 2299
3. Position the front exhaust muffler pipe to the catalytic converters. 4. Install the front exhaust
muffler pipe to the front exhaust insulator.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Install the catalytic converter nuts (1) and tighten to 45 Nm(33 lb ft). 6. Tighten the exhaust
muffler clamp at the catalytic converter (2) and tighten to 43 Nm (32 lb ft).
7. Remove the block of wood (5) from between the frame (4) and rear axle (6). 8. Install the right
rear leaf spring bolt (1) and nut (2) and tighten to 85 Nm (63 lb ft). 9. Install the lower shock
absorber bolts (8) and nuts (9) and tighten to 95 Nm (70 lb ft).
10. Inspect the exhaust system for leaks and underbody contact. 11. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust
Pipe Gasket > Component Information > Service and Repair
Exhaust Pipe Gasket: Service and Repair
Exhaust Seal Replacement (With LH8) (5.3L)
Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions).
Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician
Safety Information/Protective Goggles and Glove Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. If removing the left side seal, remove the
catalytic converter to exhaust manifold nuts (1). 3. Position the catalytic converter rearward enough
in order to allow clearance to remove the seal. 4. Remove and discard the exhaust manifold seal
(2).
5. If removing the right side seal, remove the catalytic converter to exhaust manifold nuts (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust
Pipe Gasket > Component Information > Service and Repair > Page 2304
6. Position the catalytic converter rearward enough in order to allow clearance to remove the seal.
7. Remove and discard the exhaust manifold seal (1).
Installation Procedure
1. If the right side seal was removed, position the catalytic converter rearward enough in order to
allow clearance to install the seal. 2. Install a NEW exhaust manifold seal (1).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the catalytic converter to exhaust manifold nuts (2) and tighten to 50 Nm (37 lb ft.
4. If removing the left side seal, position the catalytic converter rearward enough in order to allow
clearance to install the seal. 5. Install a NEW exhaust manifold seal (2). 6. Install the catalytic
converter to exhaust manifold nuts (1) and tighten to 50 Nm (37 lb ft). 7. Lower the vehicle. 8.
Inspect for exhaust leaks.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Customer Interest for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start
Up
Body Control Module: Customer Interest Body Controls - Security Lamp ON After Start Up
TECHNICAL
Bulletin No.: 09-08-56-001
Date: March 12, 2009
Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs
(Reprogram BCM)
Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T
Note
The information contained in this bulletin applies to vehicles located in the U.S. only.
Condition
Some customers may comment that the Security Light remains illuminated after the vehicle has
started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and
Engine Control Module (ECM).
Cause
This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run"
and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM
sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the
"Crank" mode to turn the light off.
Correction
Important Do Not replace the ignition switch for this concern.
1. Verify the customer concern.
2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI.
3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the
latest software available on TIS2WEB. Refer to the
Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with
the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON
After Start Up
Body Control Module: All Technical Service Bulletins Body Controls - Security Lamp ON After Start
Up
TECHNICAL
Bulletin No.: 09-08-56-001
Date: March 12, 2009
Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs
(Reprogram BCM)
Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T
Note
The information contained in this bulletin applies to vehicles located in the U.S. only.
Condition
Some customers may comment that the Security Light remains illuminated after the vehicle has
started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and
Engine Control Module (ECM).
Cause
This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run"
and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM
sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the
"Crank" mode to turn the light off.
Correction
Important Do Not replace the ignition switch for this concern.
1. Verify the customer concern.
2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI.
3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the
latest software available on TIS2WEB. Refer to the
Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with
the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views
Body Control Module: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views > Page 2323
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views > Page 2324
15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views > Page 2325
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210
(A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control
Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to
Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views > Page 2326
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views > Page 2327
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness
Routing Views > Page 2328
Body Control Module: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Right Kick Panel Components
1 - Body Harness 2 - Instrument Panel Harness 3 - Body Control Module (BCM) 4 - X201 5 - Body
Control Module (BCM) X2 6 - Body Control Module (BCM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2329
Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2330
Body Control Module (BCM) X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2331
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2332
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2333
Body Control Module: Service and Repair
Body Control Module Replacement
Removal Procedure
Important:
* The ignition switch should be in the OFF position when connecting or disconnecting the
connectors to the body control module (BCM).
* Always disconnect the black body wiring harness connector FIRST and the gray instrument panel
(I/P) wiring harness connector LAST.
* Always connect the black body wiring harness connector FIRST and the gray I/P wiring harness
LAST.
* Do not open the BCM housing. The module does not have any serviceable components. The
module may be replaced only as an assembly.
1. Ensure the ignition switch is in the OFF position. 2. Remove the right front hinge pillar trim panel.
Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
3. Disconnect the body wiring harness electrical connector (1) from the BCM.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2334
4. Disconnect the I/P wiring harness electrical connector (1) from the BCM.
5. Release the fastener retaining the body wiring harness electrical connector to the BCM.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2335
6. Remove the 2 fasteners retaining the BCM to the hinge pillar. 7. Remove the BCM from the
hinge pillar by unlocking the integral tab. 8. Remove the BCM from the vehicle.
Installation Procedure
1. Position the BCM to the vehicle. 2. Attach the BCM to the hinge pillar with the integral tab. 3.
Install the 2 fasteners retaining the BCM to the hinge pillar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2336
4. Install the fastener retaining the body wiring harness electrical connector to the BCM.
5. Connect the body wiring harness electrical connector (1) to the BCM.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2337
6. Connect the I/P wiring harness electrical connector (1) to the BCM. 7. Install the right front hinge
pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and
Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
8. If installing a replacement BCM, program the BCM. Refer to Control Module References (See:
Testing and Inspection/Programming and
Relearning).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage
Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory
Usage
INFORMATION
Bulletin No.: 04-06-04-054B
Date: November 18, 2010
Subject: Info - Non-GM Parts and Accessories (Aftermarket)
Models:
2011 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed
Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate
Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System).
The recent rise and expansion of companies selling non-GM parts and accessories has made it
necessary to issue this reminder to dealers regarding GM's policy on the use and installation of
these aftermarket components.
When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to
use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs,
special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the
same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty
repairs, special policy repairs or any repairs paid for by GM.
During a warranty repair, if a GM original equipment part is not available through GM Customer
Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources,
the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order
the circumstances surrounding why non-GM parts were used. The dealer must give customers
written notice, prior to the sale or service, that such parts or accessories are not marketed or
warranted by General Motors.
It should also be noted that dealers modifying new vehicles and installing equipment, parts and
accessories obtained from sources not authorized by GM are responsible for complying with the
National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed
by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design
characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully
understand that non-GM approved parts may not have been validated, tested or certified for use.
This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part
failure occurs as the result of the installation or use of a non-GM approved part, the warranty will
not be honored.
A good example of non-authorized modification of vehicles is the result of an ever increasing
supply of aftermarket devices available to the customer, which claim to increase the horsepower
and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to
one or more of the following modifications:
- Propane injection
- Nitrous oxide injection
- Additional modules (black boxes) that connect to the vehicle wiring systems
- Revised engine calibrations downloaded for the engine control module
- Calibration modules which connect to the vehicle diagnostic connector
- Modification to the engine turbocharger waste gate
Although the installation of these devices, or modification of vehicle components, can increase
engine horsepower and torque, they may also negatively affect the engine emissions, reliability
and/or durability. In addition, other powertrain components, such as transmissions, universal joints,
drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the
installation of these devices.
General Motors does not support or endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or
06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for
calibration verification.
These same policies apply as they relate to the use of non-GM accessories. Damage or failure
from the use or installation of a non-GM accessory will not be covered under warranty. Failure
resulting from the alteration or modification of the vehicle, including the cutting, welding or
disconnecting of the vehicle's original equipment parts and components will void the warranty.
Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal
inquiry at either the local, state or federal level that
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Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2342
results from the alteration or modification of a vehicle using non-GM approved parts or accessories.
Dealers should be especially cautious of accessory companies that claim the installation of their
product will not void the factory warranty. Many times these companies have even given direction
on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from
finding out that is has been installed.
Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada
by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair
is to be made on the vehicle, even with the installation of such non-GM approved components, the
customer is to be made aware of General Motors position on this issue and is to sign the
appropriate goodwill documentation required by General Motors.
It is imperative for dealers to understand that by installing such devices, they are jeopardizing not
only the warranty coverage, but also the performance and reliability of the customer's vehicle.
Disclaimer
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Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2343
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2344
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2345
2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2346
Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
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Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2347
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026B
Date: April 07, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2010 model year and information about
retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number
09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle)
to stresses that were not tested by General Motors. It is because of these unknown stresses, and
the potential to alter reliability, durability and emissions performance, that GM has adopted a policy
that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty
coverage, to the powertrain and driveline components whenever the presence of a non-GM
(aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2348
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2349
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the
complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2350
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness
Routing Views
Engine Control Module: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness
Routing Views > Page 2353
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness
Routing Views > Page 2354
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C
Refrigerant Pressure Sensor (C60)
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Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness
Routing Views > Page 2355
Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness
Routing Views > Page 2356
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Rear of the Engine Compartment Components - 1 of 2
1 - Engine Control Module (ECM) 2 - Front Plenum Panel
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2357
Engine Control Module: Diagrams
Component Connector End Views
Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2358
Engine Control Module (ECM) X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2359
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2360
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2361
Engine Control Module (ECM) X3
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2363
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2364
Engine Control Module: Description and Operation
Engine Control Module Description
The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent
driveability and fuel economy. The engine control module (ECM) is the control center of this
system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors
the information from various sensors and other inputs, and controls the systems that affect vehicle
performance and emissions. The ECM also performs the diagnostic tests on various parts of the
system. The ECM can recognize operational problems and alert the driver via the malfunction
indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble
code (DTC). The problem area is identified by the particular DTC that is set. The control module
supplies a buffered voltage to various sensors and switches. Review the components and wiring
diagrams in order to determine which systems are controlled by the ECM.
Malfunction Indicator Lamp (MIL) Operation
The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display
as either SERVICE ENGINE SOON or one of the following symbols when commanded ON:
The MIL indicates that an emissions related fault has occurred and vehicle service is required.
The following is a list of the modes of operation for the MIL:
* The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to
ensure the MIL is able to illuminate.
* The MIL turns OFF after the engine is started if a diagnostic fault is not present.
* The MIL remains illuminated after the engine is started if the control module detects a fault. A
diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an
emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test
Passed has been reported for the diagnostic test that originally caused the MIL to illuminate.
* The MIL flashes if the control module detects a misfire condition which could damage the catalytic
converter.
* When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the
ignition is ON.
* When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition
is cycled OFF and then ON.
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Engine Control Module: Service and Repair
Engine Control Module Replacement
Service of the engine control module (ECM) should normally consist of either replacement of the
ECM or electrically erasable programmable read only memory (EEPROM) programming. If the
diagnostic procedures call for the ECM to be replaced, the ECM should be inspected first to see if
the correct part is being used. If the correct part is being used, remove the faulty ECM and install
the new service ECM.
Caution:
* Turn the ignition OFF when installing or removing the control module connectors and
disconnecting or reconnecting the power to the control module (battery cable, powertrain control
module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control
module fuse, jumper cables, etc.) in order to prevent internal control module damage.
* Control module damage may result when the metal case contacts battery voltage. DO NOT
contact the control module metal case with battery voltage when servicing a control module, using
battery booster cables, or when charging the vehicle battery.
* In order to prevent any possible electrostatic discharge damage to the control module, do no
touch the connector pins or the soldered components on the circuit board.
* Remove any debris from around the control module connector surfaces before servicing the
control module. Inspect the control module connector gaskets when diagnosing or replacing the
control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant
intrusion into the control module.
* The replacement control module must be programmed.
Note: It is necessary to record the remaining engine oil life. If the replacement module is not
programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the
replacement module is not programmed with the remaining engine oil life, the engine oil will need
to be changed at 5 000 km (3,000 mi) from the last engine oil change.
Removal Procedure
1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine
oil life. 2. Remove the windshield washer solvent container. Refer to Windshield Washer Solvent
Container Replacement (See: Wiper and Washer
Systems/Windshield Washer Reservoir/Service and Repair).
3. Disengage the integral connector position assurance (CPA) retainer (1) on the body wiring
harness electrical connector. 4. Disconnect the body wiring harness electrical connector (2) from
the ECM.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2366
5. Disengage the integral CPA retainers on the engine wiring harness electrical connectors. 6.
Disconnect the engine wiring harness electrical connectors (2) from the ECM.
7. Lift up the ECM bracket tabs (2) and tilt the ECM (1) towards the front of the vehicle, removing
the ECM (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2367
1. Set the bottom of the ECM (1) into the bracket, and push the top of the ECM against the bracket.
Ensure that the tabs (2) secure the ECM (1).
2. Connect the engine wiring harness electrical connectors (2) to the ECM. 3. Engage the integral
CPA retainers on the engine wiring harness electrical connectors.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2368
4. Connect the body wiring harness electrical connector (2) to the ECM. 5. Engage the integral
CPA retainer (1) on the body wiring harness electrical connector. 6. If a NEW ECM was installed,
the ECM must be programmed. Refer to Control Module References (See: Testing and
Inspection/Programming
and Relearning).
7. Install the windshield washer solvent container. Refer to Windshield Washer Solvent Container
Replacement (See: Wiper and Washer
Systems/Windshield Washer Reservoir/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 2372
Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test).
Reference Information Schematic Reference
Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning) for scan
tool information Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 2373
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or
replace the battery positive cable to the underhood fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
‹› If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
‹› If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal,
and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM
for a short to ground. If the circuit tests normal, replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming
and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and
Inspection/Programming and Relearning)
* Engine Control Module Replacement (See: Engine Control Module/Service and Repair)
* Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power
Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay
Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution
Relay/Service and Repair/Relay Replacement (Within an Electrical Center))
Repair Verification
1. Install any components that have been removed or replaced during diagnosis.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 2374
2. Perform any adjustment, programming, or setup procedures that are required when a
component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60
seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while
observing the powertrain relay circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See:
Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic
procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Diagrams
Air Injection Pump Relay: Diagrams
Component Connector End Views
Secondary Air Injection (AIR) Pump Relay (K18)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams
Fuel Pressure Control Module: Diagrams
Component Connector End Views
Fuel Pump Flow Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page
2383
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 2390
Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test).
Reference Information Schematic Reference
Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning) for scan
tool information Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 2391
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or
replace the battery positive cable to the underhood fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
‹› If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
‹› If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal,
and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM
for a short to ground. If the circuit tests normal, replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming
and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and
Inspection/Programming and Relearning)
* Engine Control Module Replacement (See: Relays and Modules - Computers and Control
Systems/Engine Control Module/Service and Repair)
* Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power
Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay
Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution
Relay/Service and Repair/Relay Replacement (Within an Electrical Center))
Repair Verification
1. Install any components that have been removed or replaced during diagnosis.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 2392
2. Perform any adjustment, programming, or setup procedures that are required when a
component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60
seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while
observing the powertrain relay circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See:
Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic
procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views
Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Behind the Left Side of the I/P Components
1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal
Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition
Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 2399
Accelerator Pedal Position Sensor: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 2400
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 2401
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner -
Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 2402
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 2403
25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to
Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to
Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33
- Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2404
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2405
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP
sensor nuts. 3. Remove the APP sensor from the vehicle.
Installation Procedure
1. Position the APP sensor over the studs.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Page 2406
2. Install the APP sensor nuts.
Tighten the APP sensor mounting nuts to 9 Nm (80 lb in).
3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure
full range of motion.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams
Air Flow Meter/Sensor: Diagrams
Component Connector End Views
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2410
Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Removal Procedure
Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not
dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do
not touch the sensing elements or allow anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct
only, to aid in installation.
1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor.
2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner
upper housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2411
Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The
arrow must point toward the engine.
1. Install the MAF/IAT sensor (2) to the air cleaner upper housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the MAF/IAT sensor screws (1).
Tighten the screws to 1.5 Nm (13 lb in).
3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Engine - Front (LH8)
1 - Throttle Body 2 - Camshaft Position (CMP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page
2415
Camshaft Position Sensor: Diagrams
Component Connector End Views
Camshaft Position (CMP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page
2416
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 2420
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 2421
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining
and Filling (Static Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See:
Engine, Cooling and Exhaust/Cooling System/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant
temperature (ECT) sensor.
3. Remove the ECT sensor (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 2422
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent. 2. Install the ECT sensor (1).
Tighten the sensor to 20 Nm (15 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the
cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 2423
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Powertrain Component Views
Engine - Right Side (LH8) (5.3L)
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
2427
Crankshaft Position Sensor: Diagrams
Component Connector End Views
Crankshaft Position (CKP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair >
Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and
Charging/Starting System/Starter Motor/Service and
Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP)
sensor.
3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the
engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair >
Crankshaft Position Sensor Replacement > Page 2430
1. Install the CKP sensor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the CKP sensor bolt.
Tighten the bolt to 25 Nm (18 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the
starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting
System/Starter Motor/Service and Repair
)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position
System Variation Learn (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair >
Crankshaft Position Sensor Replacement > Page 2431
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions) for the applicable DTC that set.
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to
Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set.
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams
Fuel Level Sensor: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 2435
Fuel Level Sensor: Service and Repair
Fuel Level Sensor Replacement
Removal Procedure
1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel
Delivery and Air Induction/Fuel Pump/Service and
Repair).
2. Disconnect the fuel level sensor electrical connector (1) from the module cover.
3. Complete the following in order to remove the fuel level sensor (1) from the module bucket:
1. Disengage the locking tabs on the sensor. 2. Slide the sensor upward from the bucket.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 2436
1. Complete the following in order to install the fuel level sensor to the module bucket.
1. Align the edges of the sensor with the slots in the module bucket. 2. Slide the sensor down into
position, ensure the locking tabs are fully engaged.
2. Connect the fuel level sensor electrical connector (1) to the module cover. 3. Install the fuel tank
module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air
Induction/Fuel Pump/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set
Fuel Tank Pressure Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0451/P0454 Set
TECHNICAL
Bulletin No.: 10-06-04-001C
Date: December 08, 2010
Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure
Sensor Cover)
Models:
2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to
November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to
November 4, 2009) 2009-2010 Pontiac G5
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System).
Condition
Some customers may comment on a check engine light. Upon further investigation, a technician
may find one of the above DTCs.
Cause
This condition may be caused by normal water accumulation or condensation blocking the air
reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If
the signal varies during an Engine Off Natural Vacuum test, a false DTC could set.
Correction
Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI
diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield,
P/N 20893611. Clear the DTCs.
Chevrolet Colorado, Silverado and GMC Canyon, Sierra
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable
adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank
straps. 5. Lower the fuel tank halfway.
6. Locate the fuel tank pressure sensor (1).
7. Install the fuel tank pressure sensor cover, GM P/N 20893611.
Chevrolet Cobalt and Pontiac G5
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page
2445
2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454
Set
Fuel Tank Pressure Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's
P0451/P0454 Set
TECHNICAL
Bulletin No.: 10-06-04-001C
Date: December 08, 2010
Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure
Sensor Cover)
Models:
2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to
November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to
November 4, 2009) 2009-2010 Pontiac G5
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System).
Condition
Some customers may comment on a check engine light. Upon further investigation, a technician
may find one of the above DTCs.
Cause
This condition may be caused by normal water accumulation or condensation blocking the air
reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If
the signal varies during an Engine Off Natural Vacuum test, a false DTC could set.
Correction
Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI
diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield,
P/N 20893611. Clear the DTCs.
Chevrolet Colorado, Silverado and GMC Canyon, Sierra
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable
adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank
straps. 5. Lower the fuel tank halfway.
6. Locate the fuel tank pressure sensor (1).
7. Install the fuel tank pressure sensor cover, GM P/N 20893611.
Chevrolet Cobalt and Pontiac G5
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454
Set > Page 2451
2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fuel Tank Pressure Sensor: > 09-01-38-002 > May > 09 > A/C - Moan/Whine
Noise Under Heavy Load
Hose/Line HVAC: All Technical Service Bulletins A/C - Moan/Whine Noise Under Heavy Load
TECHNICAL
Bulletin No.: 09-01-38-002
Date: May 14, 2009
Subject: A/C Moan and/or Whine Noise Under Heavy Load Condition (Replace A/C Suction Hose
With Updated Design)
Models:
2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3 , H3T, H3G Export All Equipped
with Engine RPO LH8
Condition
Some customers may comment on a moan and/or a whine type noise when the A/C compressor is
engaged during high system loads. These high load operating conditions include high ambient
temperatures, extended periods of idle operation and towing applications. The noise will stop
immediately when the compressor is disengaged.
Cause
This condition may be caused by the factory installed A/C suction hose lacking sufficient noise
dampening.
Correction
Install a new A/C suction hose assembly. This new hose assembly has an improved noise
dampening design. Refer to Suction Hose Replacement (LH8) in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness
Routing Views
Fuel Tank Pressure Sensor: Locations Harness Routing Views
Harness Routing Views
Chassis Harness Routing
1 - Chassis Frame 2 - Fuel Tank Pressure (FTP) Sensor 3 - Fuel Pump and Sender Assembly 4 Evaporative Emission (EVAP) Canister Vent Solenoid 5 - X402 (Chassis Harness to Right Rear
Lamp Assembly) 6 - J404 7 - X401 (Chassis Harness to Left Rear Lamp Assembly) 8 - X400
(Chassis Harness to License Lamp Harness) 9 - J403 10 - J402 11 - J400 12 - J401 13 - J310 14 X102 (Body Harness to Chassis Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness
Routing Views > Page 2464
Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views
Wheels/Vehicle Underbody Component Views
Rear of the Frame Components
1 - Evaporative Emission (EVAP) Canister Vent Solenoid 2 - Fuel Tank Pressure (FTP) Sensor 3 Fuel Pump and Sender Assembly 4 - Fuel Pump
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
2465
Fuel Tank Pressure Sensor: Diagrams
Component Connector End Views
Fuel Tank Pressure (FTP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
2466
Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor Replacement
Removal Procedure
1. Raise and support the vehicle, high enough to access the top of the fuel tank through the
wheelhouse liner. Refer to Lifting and Jacking the Vehicle
(See: Maintenance/Vehicle Lifting/Service and Repair).
2. If the vehicle is crew cab, lower the fuel tank. Refer to Fuel Tank Replacement (See: Fuel
Delivery and Air Induction/Fuel Tank/Service and
Repair).
3. Remove the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner
Replacement (See: Body and Frame/Fender/Rear
Fender/Rear Fender Liner/Service and Repair).
4. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor
(1). 5. Pull upward in order to remove the sensor from the fuel tank module.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
2467
1. Lightly lubricate the sensor seal with clean engine oil. 2. Press the sensor fully into the fuel tank
module. 3. Connect the chassis wiring harness electrical connector to the pressure sensor (1). 4.
Install the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner
Replacement (See: Body and Frame/Fender/Rear
Fender/Rear Fender Liner/Service and Repair).
5. If the vehicle is a crew cab, install the fuel tank. Refer to Fuel Tank Replacement (See: Fuel
Delivery and Air Induction/Fuel Tank/Service and
Repair).
6. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams
Intake Air Temperature Sensor: Diagrams
Component Connector End Views
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page
2471
Intake Air Temperature Sensor: Service and Repair
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Removal Procedure
Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not
dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do
not touch the sensing elements or allow anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct
only, to aid in installation.
1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor.
2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner
upper housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page
2472
Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The
arrow must point toward the engine.
1. Install the MAF/IAT sensor (2) to the air cleaner upper housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the MAF/IAT sensor screws (1).
Tighten the screws to 1.5 Nm (13 lb in).
3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Engine - Right Side (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2476
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2477
Knock Sensor: Diagrams
Component Connector End Views
Knock Sensor (KS) 1 (LH8)
Knock Sensor (KS) 2 (LH8)
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Sensor 1 Replacement
Knock Sensor: Service and Repair Knock Sensor 1 Replacement
Knock Sensor 1 Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS
retaining bolt. 4. Remove the KS (2) from the engine block.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
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Sensor 1 Replacement > Page 2481
1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals
down.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle.
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Knock Sensor: Service and Repair Knock Sensor 2 Replacement
Knock Sensor 2 Replacement
Removal Procedure
1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS)
through the wheelhouse. Refer to Lifting and Jacking
the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair).
2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body
and Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS
retaining bolt. 5. Remove the KS (1) from the engine block.
Installation Procedure
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Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals
rearward.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left
wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and
Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
4. Lower the vehicle.
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Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Powertrain Component Views
Engine - Right Side (LH8)
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
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Page 2487
Manifold Pressure/Vacuum Sensor: Diagrams
Component Connector End Views
Manifold Absolute Pressure (MAP) Sensor
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Page 2488
Manifold Pressure/Vacuum Sensor: Service and Repair
Manifold Absolute Pressure Sensor Replacement
Removal Procedure
1. Remove the upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute
pressure (MAP) sensor.
3. Remove the MAP sensor retainer (1) from the intake manifold. 4. Remove the MAP sensor (2)
from the intake manifold.
Installation Procedure
Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor.
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Page 2489
1. Install the MAP sensor (2) into the intake manifold. 2. Install the MAP sensor retainer (2) to the
intake manifold.
3. Connect the engine wiring harness electrical connector (3) to the MAP sensor. 4. Install the
upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Special Tools
J 41712 Oil Pressure Switch Socket
Removal Procedure
1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and
Repair).
2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor.
3. If not equipped with active fuel management perform the following step, using J 41712 or
equivalent, remove the oil pressure sensor (706) and
washer (707).
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2493
4. If equipped with active fuel management perform the following step, using J 41712 or equivalent,
remove the oil pressure sensor (706) and
washer (707).
Installation Procedure
1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids,
Lubricants, and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. If equipped with active fuel management perform the following step, using J 41712 or equivalent.
Install the oil pressure sensor (706) and washer
(707). Tighten the sensor to 35 Nm (26 lb ft).
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3. If not equipped with active fuel management, perform the following step, using J 41712 or
equivalent. Install the oil pressure sensor (706) and
washer (707).
4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the
sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement
(See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and
Repair).
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations
Oxygen Sensor: Locations
Powertrain Component Views
Rear of the Transmission Components
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2498
Oxygen Sensor: Diagrams
Component Connector End Views
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 (LH8)
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 (LH8)
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Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (LH8)
Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (LH8)
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive
Force and Oxygen Sensor Caution
Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution
Excessive Force and Oxygen Sensor Caution
Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
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Force and Oxygen Sensor Caution > Page 2503
Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution
Heated Oxygen and Oxygen Sensor Caution
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
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Force and Oxygen Sensor Caution > Page 2504
Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution
Heated Oxygen Sensor Resistance Learn Reset Caution
Caution: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
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Force and Oxygen Sensor Caution > Page 2505
Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution
Silicon Contamination of Heated Oxygen Sensors Caution
Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
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Oxygen Sensor Replacement - Bank 1 Sensor 1
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4)
from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the
rear HO2S electrical connector.
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Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2508
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
4. Remove the HO2S (1).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2509
2. Install the HO2S (1).
Tighten the sensor to 42 Nm (31 lb ft).
3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S
electrical connector (4) to the engine wiring harness electrical connector (1). 5. Lower the vehicle.
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Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2510
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2)
from the engine wiring harness electrical connector (3).
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Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2511
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
3. Remove the HO2S (2).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
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Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2512
2. Install the HO2S (2).
Tighten the sensor to 42 Nm (31 lb ft).
3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the
HO2S electrical connector (2) to the engine wiring harness electrical connector (3). 5. Lower the
vehicle.
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Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2513
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1
Heated Oxygen Sensor Replacement - Bank 2 Sensor 1
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2)
from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the
rear HO2S electrical connector.
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Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2514
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
4. Remove the HO2S (1).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2515
2. Install the HO2S (1).
Tighten the sensor to 42 Nm (31 lb ft).
3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S
electrical connector (2) to the engine wiring harness electrical connector (1). 5. Lower the vehicle.
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Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2516
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2
Heated Oxygen Sensor Replacement - Bank 2 Sensor 2
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4)
from the engine wiring harness electrical connector (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2517
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
3. Remove the HO2S (2).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2518
2. Install the HO2S (2).
Tighten the sensor to 42 Nm (31 lb ft).
3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the
HO2S electrical connector (4) to the engine wiring harness electrical connector (3). 5. Lower the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations
Transmission Position Switch/Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Left Side of the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2522
1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2523
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2524
Transmission Position Switch/Sensor: Diagrams
Component Connector End Views
Park/Neutral Position (PNP) Switch (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2525
Transmission Position Switch/Sensor: Service and Repair
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
2. Remove the following parts: (89), (92), (88), (85) and (84)
3. Remove the manual shaft seal (82) with a screwdriver.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2526
1. Inspect the following items:
* Manual shaft (84) for damage or burrs
* Parking lock actuator assembly (85) for damage
* Manual shift detent lever with shaft position switch assembly (88) for damage or cracks
* Manual valve link (89) for damage
* Manual shift detent lever pin (92) discard - Do NOT reuse.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the following items:
* Manual shift detent lever with shaft position switch assembly (88)
* Parking lock actuator assembly (85)
* Manual shaft (84) (model dependent)
* NEW manual shift detent lever pin (92)
* Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft).
3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Vehicle Speed Sensor: Locations
Powertrain Component Views
Left Side of the Transmission Components (MA5)
Description
1 - Vehicle Speed Sensor (VSS)
Inside the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2530
36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift
Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid
Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC)
Pulse Width Modulation (PWM) Solenoid Valve
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2531
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2532
Vehicle Speed Sensor: Diagrams
Component Connector End Views
Vehicle Speed Sensor (VSS)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair >
Aisin AR5 - Manual Transmission
Vehicle Speed Sensor: Service and Repair Aisin AR5 - Manual Transmission
Vehicle Speed Sensor Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the vehicle speed sensor (VSS) electrical connector (2).
3. Remove the VSS with O-ring seal.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair >
Aisin AR5 - Manual Transmission > Page 2535
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
1. Install the VSS with O-ring seal.
Tighten the vehicle speed sensor (VSS) to 17 Nm (13 lb ft).
2. Connect the VSS electrical connector (2). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Aisin AR5 - Manual Transmission > Page 2536
Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission
Vehicle Speed Sensor Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the wiring harness electrical
connector from the vehicle speed sensor.
3. Remove the harness connector. 4. Remove the bolt (2). 5. Remove the vehicle speed sensor
(1). 6. Remove the O-ring seal (3).
Installation Procedure
1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin
film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the bolt (2) and tighten to 11 Nm (97 lb in). 5. Connect the wiring harness electrical
connector to the vehicle speed sensor. 6. Lower the vehicle. 7. Refill the fluid as required.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views
Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Behind the Left Side of the I/P Components
1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal
Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition
Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 2542
Accelerator Pedal Position Sensor: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 2543
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 2544
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner -
Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 2545
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 2546
25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to
Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to
Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33
- Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2547
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2548
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP
sensor nuts. 3. Remove the APP sensor from the vehicle.
Installation Procedure
1. Position the APP sensor over the studs.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2549
2. Install the APP sensor nuts.
Tighten the APP sensor mounting nuts to 9 Nm (80 lb in).
3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure
full range of motion.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams
Air Flow Meter/Sensor: Diagrams
Component Connector End Views
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2553
Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Removal Procedure
Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not
dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do
not touch the sensing elements or allow anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct
only, to aid in installation.
1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor.
2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner
upper housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2554
Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The
arrow must point toward the engine.
1. Install the MAF/IAT sensor (2) to the air cleaner upper housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the MAF/IAT sensor screws (1).
Tighten the screws to 1.5 Nm (13 lb in).
3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Engine - Front (LH8)
1 - Throttle Body 2 - Camshaft Position (CMP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2559
Camshaft Position Sensor: Diagrams
Component Connector End Views
Camshaft Position (CMP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2560
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Powertrain Component Views
Engine - Right Side (LH8) (5.3L)
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2564
Crankshaft Position Sensor: Diagrams
Component Connector End Views
Crankshaft Position (CKP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft
Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and
Charging/Starting System/Starter Motor/Service and
Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP)
sensor.
3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the
engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft
Position Sensor Replacement > Page 2567
1. Install the CKP sensor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the CKP sensor bolt.
Tighten the bolt to 25 Nm (18 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the
starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting
System/Starter Motor/Service and Repair
)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position
System Variation Learn (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft
Position Sensor Replacement > Page 2568
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions) for the applicable DTC that set.
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to
Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set.
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
This vehicle has two different types of ignition lock cylinders based on what type of steering column
the vehicle is equipped with. The electric power steering (EPS) option, usually found on 4 cylinder
models, and the non EPS, usually found on 6 cylinder models, use different ignition lock cylinder
designs.
Ignition Lock Cylinder
The ignition lock cylinder uses all 10 key cut positions, 1-10 when counting from the key head. The
tumbler orientations alternate in adjacent locations from side to side with 5 tumblers on each side.
Important: The ignition lock cylinder tumblers (1) are not self retaining and must be held in place if
the key is not fully inserted in the lock cylinder (2), or until the lock cylinder (2) is assembled into
the case assembly (5).
1. Hold the uncoded cylinder assembly (2) positioned so the side with the security plug (3) faces to
the left of the key head. 2. Insert one tumbler spring (7) into each of the 4 tumbler spring holes. 3.
The first tumbler (1) to be loaded will be key cut position 1, the first number in the key code. Install
this tumbler in the tumbler slot closest to the
head of the lock cylinder (2), the end where the key is inserted.
4. Advancing one tumbler slot at a time, install tumblers 3, 5, and 7 sequentially on the same side
as tumbler 1. 5. Turn the lock cylinder over and insert one tumbler spring (7) into each of the 4
tumbler spring holes on the opposite side of the lock cylinder. 6. Insert tumbler 2 into the tumbler
slot closest to the head of the lock cylinder (2), the end where the key is inserted. 7. Advancing one
tumbler slot at a time, install tumblers 4, 6, and 8 sequentially on the same side as tumbler 2. 8.
Check for correct tumbler loading by holding the tumblers (1) in position and inserting the correct
key into the lock cylinder. All tumblers (1)
should be flush with the housing of the lock cylinder.
9. Lightly lubricate the tumblers and small detent recessed areas the tumblers are in with GM
Super Lube GM P/N 12346241 or equivalent light
lithium grease.
10. Take the slide piece and insert into the rotor. Ensure "Front of Sliding Piece" is facing the front
face of the rotor. If the slide piece is installed
incorrectly, the key cannot insert into the rotor due to no access to the ramp.
11. Install the pivot pin into the actuator lever and install the actuator lever into the ignition lock
cylinder housing. Ensure that the actuator lever is
inside of the lock cylinder housing at the end close to key insertion opening. Actuator lever should
pivot on the pin against spring tension.
12. Insert the key into the coded lock cylinder (2) and hold the lock cylinder positioned so the side
with the security plug (3) faces to the left of the key
head.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Procedures > Page 2574
13. Hold the ignition lock housing positioned so the security plug actuator lever (3) also faces to the
right of the key head. 14. Push the exposed end of the security plug actuator lever (3) toward the
center of the lock cylinder housing (1) and hold it. Insert the coded lock
cylinder (2) with the key in it into the ignition lock cylinder housing (1) until the cap is flush with the
housing.
15. Rotate the keyed lock cylinder counterclockwise slightly until it stops and detents outward
slightly. The key should be able to be removed and the
lock cylinder should remain in the housing.
16. Install the retaining clip (1) onto the coded lock cylinder where it comes out of the back of the
lock cylinder housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Procedures > Page 2575
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Removal Procedure
1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition
Lock Cylinder Replacement). 2. Remove the multifunction turn signal switch housing. Refer to
Multifunction Turn Signal Switch Housing Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch
Housing Replacement).
3. Remove the shear bolt from the ignition lock cylinder case using a hammer and chisel. 4.
Remove the ignition lock cylinder case.
Installation Procedure
1. Install the ignition lock cylinder case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the ignition lock cylinder case bolt and tighten it until the head shears off. 3. Install the
multifunction turn signal switch. Refer to Multifunction Turn Signal Switch Housing Replacement
(See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch
Housing Replacement).
4. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock
Cylinder Replacement). 5. The passlock sensor is part of the ignition switch. If replacing the ignition
switch, a passlock relearn will be needed. Refer to Control Module
References (See: Testing and Inspection/Programming and Relearning).
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Removal Procedure
1. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
2. Turn the ignition lock cylinder to the accessory position. 3. Insert the 90 degree tip of a pick type
tool into the ignition lock cylinder access hole. 4. Push and hold the ignition lock cylinder retaining
pin down.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Procedures > Page 2576
5. Pull the ignition lock cylinder away from the steering column.
Installation Procedure
1. Install the ignition lock cylinder by performing the following procedure:
1. Turn the ignition lock cylinder to the accessory position. 2. Push the ignition lock cylinder in until
the retaining pin locks it in place.
2. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Engine - Right Side (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2580
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2581
Knock Sensor: Diagrams
Component Connector End Views
Knock Sensor (KS) 1 (LH8)
Knock Sensor (KS) 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2582
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement
Knock Sensor: Service and Repair Knock Sensor 1 Replacement
Knock Sensor 1 Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS
retaining bolt. 4. Remove the KS (2) from the engine block.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement
> Page 2585
1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals
down.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement
> Page 2586
Knock Sensor: Service and Repair Knock Sensor 2 Replacement
Knock Sensor 2 Replacement
Removal Procedure
1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS)
through the wheelhouse. Refer to Lifting and Jacking
the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair).
2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body
and Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS
retaining bolt. 5. Remove the KS (1) from the engine block.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement
> Page 2587
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals
rearward.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left
wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and
Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Specifications
Fuel Pressure: Specifications
Fuel pressure (Ignition ON, engine OFF).............................................................................................
..............................................345-414 kPa (50-60 psi) fuel pressure should not decrease more than
34 kPa (5 psi) in 1 minute
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Specifications > Page 2592
Fuel Pressure: Service Precautions
Relieving Fuel Pressure Warning
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Specifications > Page 2593
Fuel Pressure: Testing and Inspection
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category.
Circuit/System Description
The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when
the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for
2 seconds unless the engine is in Crank or Run. While this voltage is being received, the FPCM
closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump
module in order to maintain the desired fuel rail pressure.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel
pump module, eliminating the need for a return pipe from the engine. A returnless fuel system
reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the
fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.
The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump
module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and
the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of the
flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump
located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel
pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the
correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow
check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed
pipe and the fuel rail in order to prevent long cranking times.
Electrical Information Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning)for scan
tool information Special Tools
* CH 48027 - Fuel Pressure Gage
* J 37287 - Fuel Line Shut-Off Adapters
Circuit/System Verification
Note: *
Inspect the fuel system for damage or external leaks before proceeding.
* Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
1. Ignition OFF, all accessories OFF, install the CH 48027 - Gage. Refer to Fuel Pressure Gage
Installation and Removal (See: Fuel Filter/Fuel
Pressure Release/Service and Repair/Fuel Pressure Gage Installation and Removal).
2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is
between 345-414 kPa (50-60 psi) and remains steady
for 5 minutes.
Circuit/System Testing
Note: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure
gage while the fuel pump is operating. Verify the
fuel pressure is between 345-414 kPa (50-60 psi).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Specifications > Page 2594
‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel
pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the
items listed below. If all items test
normal, replace the fuel pump.
* Restricted fuel feed pipe
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
Note: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump
stops operating, the fuel pressure should stabilize and remain constant.
2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
‹› If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See:
Fuel Filter/Fuel Pressure Release/Service and
Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)).
2. Install the J 37287 - Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the
valve on the J 37287 - Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a
scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 Shut-Off Adapters. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1
minute.
‹› If the fuel pressure drops, locate and replace the leaking fuel injector.
7. If the fuel system test normal, replace the fuel pump.
3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
‹› If the fuel pressure decreases more than the specified value, replace the fuel pump.
4. Operate the vehicle within the Conditions of the customer's concern while monitoring the fuel
pressure with the CH 48027 - Gage. The fuel
pressure should not drop off during acceleration, cruise or hard cornering.
‹› If the fuel pressure drops off, test, inspect and repair the items listed below. If all items test
normal, replace the fuel sender.
* Restricted fuel feed pipe
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and
Control Systems/Testing and Inspection/Symptom
Related Diagnostic Procedures/Symptoms - Engine Controls).
Repair Instructions
Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures) after completing the diagnostic procedure.
* Fuel Hose/Pipes Replacement - Chassis (See: Fuel Delivery and Air Induction/Fuel Return
Line/Service and Repair)
* Fuel Injector Replacement (See: Fuel Delivery and Air Induction/Fuel Injector/Service and
Repair/Removal and Replacement)
* Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel
Pump/Service and Repair)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner
Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Resonator Outlet Duct Replacement
Removal Procedure
1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement
(See: Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct.
3. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner
Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2599
4. Loosen the air cleaner outlet duct clamp (1) at the throttle body. 5. Grasp the air cleaner outlet
duct near the ball stud and firmly pull up in order to disengage the duct from the ball stud. 6.
Remove the air cleaner outlet duct (2) from the throttle body and the air cleaner housing.
Installation Procedure
1. Install the air cleaner outlet duct (2) to the throttle body and the air cleaner housing. 2. Ensure
that the air cleaner outlet duct tab rests over the ball stud, press down on the duct tab in order to
engage the duct to the ball stud.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the air cleaner outlet duct clamp (1) at the throttle body.
Tighten the clamp to 3.5 Nm (31 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner
Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2600
4. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing.
Tighten the clamp to 3.5 Nm (31 lb in).
5. Install the PCV line (1) to the air cleaner outlet duct. 6. Install the intake manifold cover. Refer to
Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner
Housing > Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Air Cleaner Fresh Air Duct/Hose/Service and
Repair).
2. Release the air cleaner upper housing retainer clips (1).
3. Open the air cleaner upper housing (1). 4. Remove the air filter element (2) from the lower air
cleaner housing. 5. Inspect the air cleaner assembly for debris or damage and repair as necessary.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner
Housing > Air Filter Element > Component Information > Service and Repair > Page 2604
1. Install the air filter element (2) to the lower air cleaner housing. 2. Close the air cleaner upper
housing (1).
3. Latch the air cleaner upper housing retainer clips (1). 4. Install the air cleaner outlet duct. Refer
to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service
and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning
(See: Fuel Delivery and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID).
2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine
cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail
service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten
the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 2610
Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery
and Air Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel
Pressure Relief (With CH 48027))Fuel Pressure
Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)).
2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or
diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's
directions.
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 2611
1. Relieve the fuel system pressure, if required. Perform the following steps:
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from
the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the
fuel rail service port cap. 6. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 2612
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH-48027)
Special Tools
CH-48027 - Digital Pressure Gage
Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air
Induction/Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID).
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 2613
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT
necessary to proceed with the following steps.
12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4)
from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and
place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the
engine cover, if required. 17. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Firing Order: Specifications
Ignition System Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Testing and Inspection
Ignition Cable: Testing and Inspection
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to
accurately identify conditions that may affect engine operation. Inspect for the following conditions:
1. Correct routing of the spark plug wires - Incorrect routing may cause cross-firing. 2. Any signs of
cracks or splits in the wires. 3. Inspect each boot for the following conditions:
* Tearing
* Piercing
* Arcing
* Carbon tracking
* Corroded terminal
If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace
the wire and the component connected to the wire.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Testing and Inspection > Page 2620
Ignition Cable: Service and Repair
Spark Plug Wire Replacement
Removal Procedure
1. Remove the spark plug wire from the spark plug.
* Twist each spark plug 1/2 turn.
* Pull only on the boot in order to remove the wire from each spark plug.
2. Remove the spark plug wire from the ignition coil.
* Twist each spark plug boot 1/2 turn.
* Pull only on the boot in order to remove the wires from the ignition coil.
Installation Procedure
1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3.
Inspect the wires for proper installation:
* Push sideways on each boot in order to inspect the seating.
* Reinstall any loose boot.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 >
Ignition System - Runs Rough MIL/ON DTC P0300/P0306
Spark Plug: Customer Interest Ignition System - Runs Rough MIL/ON DTC P0300/P0306
TECHNICAL
Bulletin No.: 09-06-04-025A
Date: December 20, 2010
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs
Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition
Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille)
Models:
2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER
H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to
GWM/IMH
Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification
section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion
System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) is illuminated.
Some customers may also comment that the engine runs rough.
The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as
current or in history, depending on which engine the vehicle is equipped with.
Upon further examination, the technician may observe evidence of water intrusion into the spark
plug recess area.
Cause
This condition may be caused by an engine being exposed to a large quantity of water, which may
result in some of the water seeping down past the vented threads of an ignition coil bolt, then
flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole,
and collecting in the spark plug recess area.
Correction
Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If
evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the
appropriate DTC procedures in SI.
1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the
affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner
Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical
connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove
the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil
Replacement in SI.
Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply
Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads.
5. Inspect for water intrusion in the spark plug recess areas.
Warning
Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
6. If any water is present, then remove the water from the spark plug recess areas with low
pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug
Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed
into the cylinder head. Refer to Spark Plug Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 >
Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2629
9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as
indicated in the illustration, and apply it to the
ignition coil bolt threads also.
10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition
Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition
coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet
duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a
scan tool.
Hood Grille Modification for HUMMER H3 Vehicles Only
Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall
#10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall
#10088A has been performed on the vehicle, DO NOT perform the following hood grille
modification.
1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille
Replacement (H3T) in SI.
2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention
clip (1) opening in the vehicle hood (all 4
sides of the rectangular slot).
3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly
against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement
(H3T) in SI.
5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme
water pressure should not be directly applied to the
edges of the hood air grille.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 >
Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2630
from other sources.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A >
Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306
Spark Plug: All Technical Service Bulletins Ignition System - Runs Rough MIL/ON DTC
P0300/P0306
TECHNICAL
Bulletin No.: 09-06-04-025A
Date: December 20, 2010
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs
Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition
Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille)
Models:
2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER
H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to
GWM/IMH
Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification
section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion
System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) is illuminated.
Some customers may also comment that the engine runs rough.
The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as
current or in history, depending on which engine the vehicle is equipped with.
Upon further examination, the technician may observe evidence of water intrusion into the spark
plug recess area.
Cause
This condition may be caused by an engine being exposed to a large quantity of water, which may
result in some of the water seeping down past the vented threads of an ignition coil bolt, then
flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole,
and collecting in the spark plug recess area.
Correction
Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If
evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the
appropriate DTC procedures in SI.
1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the
affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner
Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical
connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove
the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil
Replacement in SI.
Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply
Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads.
5. Inspect for water intrusion in the spark plug recess areas.
Warning
Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
6. If any water is present, then remove the water from the spark plug recess areas with low
pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug
Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed
into the cylinder head. Refer to Spark Plug Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A >
Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2636
9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as
indicated in the illustration, and apply it to the
ignition coil bolt threads also.
10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition
Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition
coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet
duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a
scan tool.
Hood Grille Modification for HUMMER H3 Vehicles Only
Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall
#10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall
#10088A has been performed on the vehicle, DO NOT perform the following hood grille
modification.
1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille
Replacement (H3T) in SI.
2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention
clip (1) opening in the vehicle hood (all 4
sides of the rectangular slot).
3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly
against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement
(H3T) in SI.
5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme
water pressure should not be directly applied to the
edges of the hood air grille.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A >
Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2637
from other sources.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Page 2638
Spark Plug: Specifications
Ignition System Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Page 2639
Spark Plug: Application and ID
Ignition System Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Page 2640
Spark Plug: Testing and Inspection
Spark Plug Inspection
* Verify that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications ( See: Ignition System/Specifications) for the
correct spark plug.
* Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling - Colder plug
- Pre-ignition causing spark plug and/or engine damage - Hotter plug
* Inspect the terminal post (1) for damage.
- Inspect for a bent or broken terminal post (1)
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post should not
move.
* Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical
charge traveling across the insulator between the terminal post (1) and ground. Inspect for the
following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess are of the cylinder head for moisture, such as oil, coolant, or water.
A spark plug boot that is saturated will cause arcing to ground.
* Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack
instead of the electrodes (3,4).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Page 2641
* Inspect for evidence of improper arcing.
- Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition
System Specifications (See: Ignition System/Specifications). An excessively wide electrode gap
can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Ignition
System/Specifications). Insufficient torque can prevent correct spark plug operation. An over
torqued spark plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
* A rattling sound indicates internal damage.
* A looses center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3,4). Deposits on the electrodes (3,4) reduce or eliminates the
gap.
- Inspect for worn or missing platinum pads on the electrodes (3,4), if equipped.
- Inspect for excessive fouling.
* Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during installation.
Visual Inspection
* Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are
normal combustion by-products from fuels with additives.
* Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions:
- Rich fuel mixtures
* Leaking fuel injectors
* Excessive fuel pressure
* Restricted air filter element
* Incorrect combustion
- Reduced ignition system voltage output
* Weak ignition coils
* Worn ignition wires
* Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that
normal combustion deposits may not burn off.
* Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white
coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity
unless they form into a glazing over the electrode.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Page 2642
Spark Plug: Service and Repair
Spark Plug Replacement
Removal Procedure
1. Remove the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition
Cable/Service and Repair). 2. Loosen the spark plug 1-2 turns. 3. Brush or using compressed air,
blow away any dirt from around the spark plug. 4. Remove the spark plug.
If removing more than one plug, place each plug in a tray marked with the corresponding cylinder
number.
Installation Procedure
1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as
needed. Refer to Ignition System Specifications (See: Ignition System/Specifications). 3. Hand start
the spark plug in the corresponding cylinder.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Tighten the spark plug.
Tighten the plug to 20 Nm (15 lb ft).
5. Install the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition Cable/Service
and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression
Check > System Information > Specifications
Compression Check: Specifications
COMPRESSION CHECK
If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the
combustion chamber through the spark plug hole. Measure the compression again and record the
reading. The minimum compression in any 1 cylinder should not be less than 70 percent of the
highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest
pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other
cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression
Check > System Information > Specifications > Page 2646
Compression Check: Testing and Inspection
Engine Compression Test
1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable
the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6.
Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression
gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the
compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject
approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark
plug
hole. Measure the compression again and record the reading.
10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690 kPa
(100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest
allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x
70% = 105).
* Normal - Compression builds up quickly and evenly to the specified compression for each
cylinder.
* Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the
following strokes, but does not reach normal. Compression improves considerably when you add
oil.
* Valves Leaking - Compression is low on the first stroke. Compression usually does not build up
on the following strokes. Compression does not improve much when you add oil.
* If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders
does not increase the compression, the cause may be a head gasket leaking between the
cylinders.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views
Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Behind the Left Side of the I/P Components
1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal
Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition
Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2652
Accelerator Pedal Position Sensor: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2653
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2654
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2655
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2656
25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to
Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to
Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33
- Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 2657
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 2658
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP
sensor nuts. 3. Remove the APP sensor from the vehicle.
Installation Procedure
1. Position the APP sensor over the studs.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 2659
2. Install the APP sensor nuts.
Tighten the APP sensor mounting nuts to 9 Nm (80 lb in).
3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure
full range of motion.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams
Air Flow Meter/Sensor: Diagrams
Component Connector End Views
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 2663
Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Removal Procedure
Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not
dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do
not touch the sensing elements or allow anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct
only, to aid in installation.
1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor.
2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner
upper housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 2664
Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The
arrow must point toward the engine.
1. Install the MAF/IAT sensor (2) to the air cleaner upper housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the MAF/IAT sensor screws (1).
Tighten the screws to 1.5 Nm (13 lb in).
3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Diagrams
Intake Air Temperature Sensor: Diagrams
Component Connector End Views
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Diagrams > Page 2668
Intake Air Temperature Sensor: Service and Repair
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Removal Procedure
Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not
dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do
not touch the sensing elements or allow anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct
only, to aid in installation.
1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor.
2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner
upper housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Diagrams > Page 2669
Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The
arrow must point toward the engine.
1. Install the MAF/IAT sensor (2) to the air cleaner upper housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the MAF/IAT sensor screws (1).
Tighten the screws to 1.5 Nm (13 lb in).
3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 09-08-56-001 > Mar >
09 > Body Controls - Security Lamp ON After Start Up
Body Control Module: Customer Interest Body Controls - Security Lamp ON After Start Up
TECHNICAL
Bulletin No.: 09-08-56-001
Date: March 12, 2009
Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs
(Reprogram BCM)
Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T
Note
The information contained in this bulletin applies to vehicles located in the U.S. only.
Condition
Some customers may comment that the Security Light remains illuminated after the vehicle has
started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and
Engine Control Module (ECM).
Cause
This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run"
and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM
sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the
"Crank" mode to turn the light off.
Correction
Important Do Not replace the ignition switch for this concern.
1. Verify the customer concern.
2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI.
3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the
latest software available on TIS2WEB. Refer to the
Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with
the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: >
09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start Up
Body Control Module: All Technical Service Bulletins Body Controls - Security Lamp ON After Start
Up
TECHNICAL
Bulletin No.: 09-08-56-001
Date: March 12, 2009
Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs
(Reprogram BCM)
Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T
Note
The information contained in this bulletin applies to vehicles located in the U.S. only.
Condition
Some customers may comment that the Security Light remains illuminated after the vehicle has
started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and
Engine Control Module (ECM).
Cause
This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run"
and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM
sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the
"Crank" mode to turn the light off.
Correction
Important Do Not replace the ignition switch for this concern.
1. Verify the customer concern.
2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI.
3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the
latest software available on TIS2WEB. Refer to the
Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with
the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Harness Routing Views
Body Control Module: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Harness Routing Views > Page 2685
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Harness Routing Views > Page 2686
15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Harness Routing Views > Page 2687
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210
(A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control
Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to
Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Harness Routing Views > Page 2688
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Harness Routing Views > Page 2689
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Harness Routing Views > Page 2690
Body Control Module: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Right Kick Panel Components
1 - Body Harness 2 - Instrument Panel Harness 3 - Body Control Module (BCM) 4 - X201 5 - Body
Control Module (BCM) X2 6 - Body Control Module (BCM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Page 2691
Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Page 2692
Body Control Module (BCM) X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Page 2693
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Page 2694
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Page 2695
Body Control Module: Service and Repair
Body Control Module Replacement
Removal Procedure
Important:
* The ignition switch should be in the OFF position when connecting or disconnecting the
connectors to the body control module (BCM).
* Always disconnect the black body wiring harness connector FIRST and the gray instrument panel
(I/P) wiring harness connector LAST.
* Always connect the black body wiring harness connector FIRST and the gray I/P wiring harness
LAST.
* Do not open the BCM housing. The module does not have any serviceable components. The
module may be replaced only as an assembly.
1. Ensure the ignition switch is in the OFF position. 2. Remove the right front hinge pillar trim panel.
Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
3. Disconnect the body wiring harness electrical connector (1) from the BCM.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Page 2696
4. Disconnect the I/P wiring harness electrical connector (1) from the BCM.
5. Release the fastener retaining the body wiring harness electrical connector to the BCM.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Page 2697
6. Remove the 2 fasteners retaining the BCM to the hinge pillar. 7. Remove the BCM from the
hinge pillar by unlocking the integral tab. 8. Remove the BCM from the vehicle.
Installation Procedure
1. Position the BCM to the vehicle. 2. Attach the BCM to the hinge pillar with the integral tab. 3.
Install the 2 fasteners retaining the BCM to the hinge pillar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Page 2698
4. Install the fastener retaining the body wiring harness electrical connector to the BCM.
5. Connect the body wiring harness electrical connector (1) to the BCM.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Page 2699
6. Connect the I/P wiring harness electrical connector (1) to the BCM. 7. Install the right front hinge
pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and
Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
8. If installing a replacement BCM, program the BCM. Refer to Control Module References (See:
Testing and Inspection/Programming and
Relearning).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Engine - Front (LH8)
1 - Throttle Body 2 - Camshaft Position (CMP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Page 2703
Camshaft Position Sensor: Diagrams
Component Connector End Views
Camshaft Position (CMP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Page 2704
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Page 2708
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Page 2709
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining
and Filling (Static Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See:
Engine, Cooling and Exhaust/Cooling System/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant
temperature (ECT) sensor.
3. Remove the ECT sensor (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Page 2710
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent. 2. Install the ECT sensor (1).
Tighten the sensor to 20 Nm (15 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the
cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Page 2711
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations
Crankshaft Position Sensor: Locations
Powertrain Component Views
Engine - Right Side (LH8) (5.3L)
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2715
Crankshaft Position Sensor: Diagrams
Component Connector End Views
Crankshaft Position (CKP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Service and Repair > Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and
Charging/Starting System/Starter Motor/Service and
Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP)
sensor.
3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the
engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2718
1. Install the CKP sensor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the CKP sensor bolt.
Tighten the bolt to 25 Nm (18 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the
starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting
System/Starter Motor/Service and Repair
)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position
System Variation Learn (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2719
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for the
applicable DTC that set.
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P
Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle
(See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that
set.
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations > Harness Routing Views
Data Link Connector: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations > Harness Routing Views > Page 2724
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations > Harness Routing Views > Page 2725
Data Link Connector: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Below the I/P Components - 1 of 2
1 - Vehicle Communication Interface Module (VCIM) X1 (UE1) 2 - Vehicle Communication Interface
Module (VCIM) X2 (UE1) 3 - Vehicle Communication Interface Module (VCIM) (UE1) 4 - I/P
Courtesy Lamp - Right 5 - I/P Courtesy Lamp - Left 6 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations > Page 2726
Data Link Connector: Diagrams
Component Connector End Views
Data Link Connector (DLC)
Data Link Resistor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations > Page 2727
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Description and Operation
Electronic Throttle Actuator: Description and Operation
Throttle Actuator Control (TAC) System Description
Purpose
The throttle actuator control (TAC) system delivers improved throttle response and greater
reliability and eliminates the need for mechanical cable. The TAC system performs the following
functions:
* Accelerator pedal position sensing
* Throttle positioning to meet driver and engine demands
* Throttle position sensing
* Internal diagnostics
* Cruise control functions
* Manage TAC electrical power consumption
The TAC system includes the following components:
* The accelerator pedal position (APP) sensors
* The throttle body assembly
* The engine control module (ECM)
Accelerator Pedal Position (APP) Sensor
The accelerator pedal contains 2 individual APP sensors within the assembly. The Accelerator
Pedal Position (APP) sensors 1 and 2 are potentiometer type sensors each with 3 circuits:
* A 5-volt reference circuit
* A low reference circuit
* A signal circuit
The APP sensors are used to determine the pedal angle. The engine control module (ECM)
provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors
provide the ECM with signal voltage proportional to the pedal movement. The APP sensor 1 signal
voltage at rest position is less than 1 volt and increases to above 4 volts as the pedal is actuated.
The APP sensor 2 signal voltage at rest position is near 0.5 volt and increases to more than 2 volts
as the pedal is actuated.
Throttle Body Assembly
The throttle assembly contains the following components:
* The throttle blade
* The throttle actuator motor
* The throttle position (TP) sensor 1 and 2
The throttle body functions similar to a conventional throttle body with the following exceptions:
* An electric motor opens and closes the throttle valve.
* The throttle blade is spring loaded in both directions and the default position is slightly open.
* There are 2 individual TP sensors within the throttle body assembly.
The TP sensors are used to determine the throttle plate angle. The TP sensors provide the engine
control module (ECM) with a signal voltage proportional to throttle plate movement. The TP sensor
1 signal voltage at closed throttle is above 4 volts and decreases as the throttle plate is opened.
The TP sensor 2 signal voltage at closed throttle is below 1 volt and increases as the throttle plate
is opened.
Engine Control Module
The engine control module (ECM) is the control center for the throttle actuator control (TAC)
system. The ECM determines the drivers intent and then calculates the appropriate throttle
response. The ECM achieves throttle positioning by providing a pulse width modulated voltage to
the TAC motor.
Modes of Operation
Normal Mode
During the operation of the throttle actuator control (TAC) system, several modes or functions are
considered normal. The following modes may be entered during normal operation:
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Description and Operation > Page 2731
* Minimum pedal value-At key-up the engine control module (ECM) updates the learned minimum
pedal value.
* Minimum throttle position (TP) values-At key-up the ECM updates the learned minimum TP value.
In order to learn the minimum TP value, the throttle blade is moved to the closed position.
* Ice break mode-If the throttle is not able to reach a predetermined minimum throttle position, the
ice break mode is entered. During the ice break mode, the ECM commands the maximum pulse
width several times to the throttle actuator motor in the closing direction.
* Battery saver mode-After a predetermined time without engine RPM, the ECM commands the
battery saver mode. During the battery saver mode, the TAC module removes the voltage from the
motor control circuits, which removes the current draw used to maintain the idle position and allows
the throttle to return to the spring loaded default position.
Reduced Engine Power Mode
When the ECM detects a condition with the TAC system, the ECM may enter a reduced engine
power mode. Reduced engine power may cause one or more of the following conditions:
* Acceleration limiting-The ECM will continue to use the accelerator pedal for throttle control;
however, the vehicle acceleration is limited.
* Limited throttle mode-The ECM will continue to use the accelerator pedal for throttle control;
however, the maximum throttle opening is limited.
* Throttle default mode-The ECM will turn off the throttle actuator motor and the throttle will return
to the spring loaded default position.
* Forced idle mode-The ECM will perform the following actions:
- Limit engine speed to idle by positioning the throttle position, or by controlling the fuel and spark if
the throttle is turned off.
- Ignore the accelerator pedal input.
* Engine shutdown mode-The ECM will disable fuel and de-energize the throttle actuator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage
Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory
Usage
INFORMATION
Bulletin No.: 04-06-04-054B
Date: November 18, 2010
Subject: Info - Non-GM Parts and Accessories (Aftermarket)
Models:
2011 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed
Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate
Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System).
The recent rise and expansion of companies selling non-GM parts and accessories has made it
necessary to issue this reminder to dealers regarding GM's policy on the use and installation of
these aftermarket components.
When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to
use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs,
special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the
same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty
repairs, special policy repairs or any repairs paid for by GM.
During a warranty repair, if a GM original equipment part is not available through GM Customer
Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources,
the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order
the circumstances surrounding why non-GM parts were used. The dealer must give customers
written notice, prior to the sale or service, that such parts or accessories are not marketed or
warranted by General Motors.
It should also be noted that dealers modifying new vehicles and installing equipment, parts and
accessories obtained from sources not authorized by GM are responsible for complying with the
National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed
by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design
characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully
understand that non-GM approved parts may not have been validated, tested or certified for use.
This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part
failure occurs as the result of the installation or use of a non-GM approved part, the warranty will
not be honored.
A good example of non-authorized modification of vehicles is the result of an ever increasing
supply of aftermarket devices available to the customer, which claim to increase the horsepower
and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to
one or more of the following modifications:
- Propane injection
- Nitrous oxide injection
- Additional modules (black boxes) that connect to the vehicle wiring systems
- Revised engine calibrations downloaded for the engine control module
- Calibration modules which connect to the vehicle diagnostic connector
- Modification to the engine turbocharger waste gate
Although the installation of these devices, or modification of vehicle components, can increase
engine horsepower and torque, they may also negatively affect the engine emissions, reliability
and/or durability. In addition, other powertrain components, such as transmissions, universal joints,
drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the
installation of these devices.
General Motors does not support or endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or
06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for
calibration verification.
These same policies apply as they relate to the use of non-GM accessories. Damage or failure
from the use or installation of a non-GM accessory will not be covered under warranty. Failure
resulting from the alteration or modification of the vehicle, including the cutting, welding or
disconnecting of the vehicle's original equipment parts and components will void the warranty.
Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal
inquiry at either the local, state or federal level that
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2736
results from the alteration or modification of a vehicle using non-GM approved parts or accessories.
Dealers should be especially cautious of accessory companies that claim the installation of their
product will not void the factory warranty. Many times these companies have even given direction
on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from
finding out that is has been installed.
Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada
by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair
is to be made on the vehicle, even with the installation of such non-GM approved components, the
customer is to be made aware of General Motors position on this issue and is to sign the
appropriate goodwill documentation required by General Motors.
It is imperative for dealers to understand that by installing such devices, they are jeopardizing not
only the warranty coverage, but also the performance and reliability of the customer's vehicle.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2737
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2738
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2739
2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2740
Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2741
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026B
Date: April 07, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2010 model year and information about
retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number
09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle)
to stresses that were not tested by General Motors. It is because of these unknown stresses, and
the potential to alter reliability, durability and emissions performance, that GM has adopted a policy
that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty
coverage, to the powertrain and driveline components whenever the presence of a non-GM
(aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2742
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2743
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the
complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2744
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Harness Routing Views
Engine Control Module: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Harness Routing Views > Page 2747
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Harness Routing Views > Page 2748
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C
Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Harness Routing Views > Page 2749
Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Harness Routing Views > Page 2750
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Rear of the Engine Compartment Components - 1 of 2
1 - Engine Control Module (ECM) 2 - Front Plenum Panel
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Page 2751
Engine Control Module: Diagrams
Component Connector End Views
Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Page 2752
Engine Control Module (ECM) X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Page 2753
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Page 2754
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Page 2755
Engine Control Module (ECM) X3
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Page 2756
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Page 2757
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Page 2758
Engine Control Module: Description and Operation
Engine Control Module Description
The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent
driveability and fuel economy. The engine control module (ECM) is the control center of this
system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors
the information from various sensors and other inputs, and controls the systems that affect vehicle
performance and emissions. The ECM also performs the diagnostic tests on various parts of the
system. The ECM can recognize operational problems and alert the driver via the malfunction
indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble
code (DTC). The problem area is identified by the particular DTC that is set. The control module
supplies a buffered voltage to various sensors and switches. Review the components and wiring
diagrams in order to determine which systems are controlled by the ECM.
Malfunction Indicator Lamp (MIL) Operation
The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display
as either SERVICE ENGINE SOON or one of the following symbols when commanded ON:
The MIL indicates that an emissions related fault has occurred and vehicle service is required.
The following is a list of the modes of operation for the MIL:
* The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to
ensure the MIL is able to illuminate.
* The MIL turns OFF after the engine is started if a diagnostic fault is not present.
* The MIL remains illuminated after the engine is started if the control module detects a fault. A
diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an
emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test
Passed has been reported for the diagnostic test that originally caused the MIL to illuminate.
* The MIL flashes if the control module detects a misfire condition which could damage the catalytic
converter.
* When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the
ignition is ON.
* When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition
is cycled OFF and then ON.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Page 2759
Engine Control Module: Service and Repair
Engine Control Module Replacement
Service of the engine control module (ECM) should normally consist of either replacement of the
ECM or electrically erasable programmable read only memory (EEPROM) programming. If the
diagnostic procedures call for the ECM to be replaced, the ECM should be inspected first to see if
the correct part is being used. If the correct part is being used, remove the faulty ECM and install
the new service ECM.
Caution:
* Turn the ignition OFF when installing or removing the control module connectors and
disconnecting or reconnecting the power to the control module (battery cable, powertrain control
module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control
module fuse, jumper cables, etc.) in order to prevent internal control module damage.
* Control module damage may result when the metal case contacts battery voltage. DO NOT
contact the control module metal case with battery voltage when servicing a control module, using
battery booster cables, or when charging the vehicle battery.
* In order to prevent any possible electrostatic discharge damage to the control module, do no
touch the connector pins or the soldered components on the circuit board.
* Remove any debris from around the control module connector surfaces before servicing the
control module. Inspect the control module connector gaskets when diagnosing or replacing the
control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant
intrusion into the control module.
* The replacement control module must be programmed.
Note: It is necessary to record the remaining engine oil life. If the replacement module is not
programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the
replacement module is not programmed with the remaining engine oil life, the engine oil will need
to be changed at 5 000 km (3,000 mi) from the last engine oil change.
Removal Procedure
1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine
oil life. 2. Remove the windshield washer solvent container. Refer to Windshield Washer Solvent
Container Replacement (See: Wiper and Washer
Systems/Windshield Washer Reservoir/Service and Repair).
3. Disengage the integral connector position assurance (CPA) retainer (1) on the body wiring
harness electrical connector. 4. Disconnect the body wiring harness electrical connector (2) from
the ECM.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Page 2760
5. Disengage the integral CPA retainers on the engine wiring harness electrical connectors. 6.
Disconnect the engine wiring harness electrical connectors (2) from the ECM.
7. Lift up the ECM bracket tabs (2) and tilt the ECM (1) towards the front of the vehicle, removing
the ECM (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Page 2761
1. Set the bottom of the ECM (1) into the bracket, and push the top of the ECM against the bracket.
Ensure that the tabs (2) secure the ECM (1).
2. Connect the engine wiring harness electrical connectors (2) to the ECM. 3. Engage the integral
CPA retainers on the engine wiring harness electrical connectors.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Page 2762
4. Connect the body wiring harness electrical connector (2) to the ECM. 5. Engage the integral
CPA retainer (1) on the body wiring harness electrical connector. 6. If a NEW ECM was installed,
the ECM must be programmed. Refer to Control Module References (See: Testing and
Inspection/Programming
and Relearning).
7. Install the windshield washer solvent container. Refer to Windshield Washer Solvent Container
Replacement (See: Wiper and Washer
Systems/Windshield Washer Reservoir/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module
> Component Information > Technical Service Bulletins > Recalls for Fuel Injector Control Module: > NHTSA09V154000 >
May > 09 > Recall 09V154000: Fuel System Control Module Shorting
Fuel Injector Control Module: Recalls Recall 09V154000: Fuel System Control Module Shorting
VEHICLE MAKE/MODEL: MODEL YEAR(S): Cadillac/Escalade 2009 Cadillac/Escalade ESV 2009
Cadillac/Escalade EXT 2009 Chevrolet/Avalanche 2009 Chevrolet/Colorado 2009
Chevrolet/Suburban 2009 Chevrolet/Tahoe 2009 GMC/Canyon 2009 GMC/Yukon 2009
GMC/Yukon XL 2009 MANUFACTURER: General Motors Corp.
MFR'S REPORT DATE: May 06, 2009
NHTSA CAMPAIGN ID NUMBER: 09V154000
NHTSA ACTION NUMBER: N/A COMPONENT: Fuel System, Gasoline
POTENTIAL NUMBER OF UNITS AFFECTED: 27188
SUMMARY: GM is recalling 27,188 M/Y 2009 Cadillac Escalade, Escalade Hybrid, Escalade ESV,
and Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe, Tahoe Hybrid, and Colorado; and
GMC Yukon, Yukon Hybrid, Yukon XL, and Canyon vehicles. The fuel system control modules may
have a condition in which an adhesive separation of the Room Temperature Vulcanizing (RTV)
seal between the seal and the housing may allow water to seep into the module.
CONSEQUENCE: Water in the module could cause a short or open circuit, illumination of the
service engine soon lamp, setting of diagnostic trouble codes or the engine may be hard to start,
may not start or may stall increasing the risk of a crash.
REMEDY: Dealers will install a new fuel system control module free of charge. The recall is
expected to begin on or before May 18, 2009. Owners may contact Cadillac at 1-866-982-2339,
Chevrolet at 1-800-630-2438 and GMC at 1-866-996-9463 or at www.gmownercenter.com.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Control Module: >
NHTSA09V154000 > May > 09 > Recall 09V154000: Fuel System Control Module Shorting
Fuel Injector Control Module: All Technical Service Bulletins Recall 09V154000: Fuel System
Control Module Shorting
VEHICLE MAKE/MODEL: MODEL YEAR(S): Cadillac/Escalade 2009 Cadillac/Escalade ESV 2009
Cadillac/Escalade EXT 2009 Chevrolet/Avalanche 2009 Chevrolet/Colorado 2009
Chevrolet/Suburban 2009 Chevrolet/Tahoe 2009 GMC/Canyon 2009 GMC/Yukon 2009
GMC/Yukon XL 2009 MANUFACTURER: General Motors Corp.
MFR'S REPORT DATE: May 06, 2009
NHTSA CAMPAIGN ID NUMBER: 09V154000
NHTSA ACTION NUMBER: N/A COMPONENT: Fuel System, Gasoline
POTENTIAL NUMBER OF UNITS AFFECTED: 27188
SUMMARY: GM is recalling 27,188 M/Y 2009 Cadillac Escalade, Escalade Hybrid, Escalade ESV,
and Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe, Tahoe Hybrid, and Colorado; and
GMC Yukon, Yukon Hybrid, Yukon XL, and Canyon vehicles. The fuel system control modules may
have a condition in which an adhesive separation of the Room Temperature Vulcanizing (RTV)
seal between the seal and the housing may allow water to seep into the module.
CONSEQUENCE: Water in the module could cause a short or open circuit, illumination of the
service engine soon lamp, setting of diagnostic trouble codes or the engine may be hard to start,
may not start or may stall increasing the risk of a crash.
REMEDY: Dealers will install a new fuel system control module free of charge. The recall is
expected to begin on or before May 18, 2009. Owners may contact Cadillac at 1-866-982-2339,
Chevrolet at 1-800-630-2438 and GMC at 1-866-996-9463 or at www.gmownercenter.com.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor >
Component Information > Diagrams
Fuel Level Sensor: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor >
Component Information > Diagrams > Page 2779
Fuel Level Sensor: Service and Repair
Fuel Level Sensor Replacement
Removal Procedure
1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel
Delivery and Air Induction/Fuel Pump/Service and
Repair).
2. Disconnect the fuel level sensor electrical connector (1) from the module cover.
3. Complete the following in order to remove the fuel level sensor (1) from the module bucket:
1. Disengage the locking tabs on the sensor. 2. Slide the sensor upward from the bucket.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor >
Component Information > Diagrams > Page 2780
1. Complete the following in order to install the fuel level sensor to the module bucket.
1. Align the edges of the sensor with the slots in the module bucket. 2. Slide the sensor down into
position, ensure the locking tabs are fully engaged.
2. Connect the fuel level sensor electrical connector (1) to the module cover. 3. Install the fuel tank
module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air
Induction/Fuel Pump/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor
> Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: >
10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set
Fuel Tank Pressure Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0451/P0454 Set
TECHNICAL
Bulletin No.: 10-06-04-001C
Date: December 08, 2010
Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure
Sensor Cover)
Models:
2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to
November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to
November 4, 2009) 2009-2010 Pontiac G5
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System).
Condition
Some customers may comment on a check engine light. Upon further investigation, a technician
may find one of the above DTCs.
Cause
This condition may be caused by normal water accumulation or condensation blocking the air
reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If
the signal varies during an Engine Off Natural Vacuum test, a false DTC could set.
Correction
Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI
diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield,
P/N 20893611. Clear the DTCs.
Chevrolet Colorado, Silverado and GMC Canyon, Sierra
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable
adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank
straps. 5. Lower the fuel tank halfway.
6. Locate the fuel tank pressure sensor (1).
7. Install the fuel tank pressure sensor cover, GM P/N 20893611.
Chevrolet Cobalt and Pontiac G5
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor
> Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: >
10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page 2789
2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: >
10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set
Fuel Tank Pressure Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's
P0451/P0454 Set
TECHNICAL
Bulletin No.: 10-06-04-001C
Date: December 08, 2010
Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure
Sensor Cover)
Models:
2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to
November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to
November 4, 2009) 2009-2010 Pontiac G5
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System).
Condition
Some customers may comment on a check engine light. Upon further investigation, a technician
may find one of the above DTCs.
Cause
This condition may be caused by normal water accumulation or condensation blocking the air
reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If
the signal varies during an Engine Off Natural Vacuum test, a false DTC could set.
Correction
Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI
diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield,
P/N 20893611. Clear the DTCs.
Chevrolet Colorado, Silverado and GMC Canyon, Sierra
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable
adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank
straps. 5. Lower the fuel tank halfway.
6. Locate the fuel tank pressure sensor (1).
7. Install the fuel tank pressure sensor cover, GM P/N 20893611.
Chevrolet Cobalt and Pontiac G5
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: >
10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page 2795
2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor
> Component Information > Locations > Harness Routing Views
Fuel Tank Pressure Sensor: Locations Harness Routing Views
Harness Routing Views
Chassis Harness Routing
1 - Chassis Frame 2 - Fuel Tank Pressure (FTP) Sensor 3 - Fuel Pump and Sender Assembly 4 Evaporative Emission (EVAP) Canister Vent Solenoid 5 - X402 (Chassis Harness to Right Rear
Lamp Assembly) 6 - J404 7 - X401 (Chassis Harness to Left Rear Lamp Assembly) 8 - X400
(Chassis Harness to License Lamp Harness) 9 - J403 10 - J402 11 - J400 12 - J401 13 - J310 14 X102 (Body Harness to Chassis Harness)
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Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views
Wheels/Vehicle Underbody Component Views
Rear of the Frame Components
1 - Evaporative Emission (EVAP) Canister Vent Solenoid 2 - Fuel Tank Pressure (FTP) Sensor 3 Fuel Pump and Sender Assembly 4 - Fuel Pump
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Fuel Tank Pressure Sensor: Diagrams
Component Connector End Views
Fuel Tank Pressure (FTP) Sensor
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Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor Replacement
Removal Procedure
1. Raise and support the vehicle, high enough to access the top of the fuel tank through the
wheelhouse liner. Refer to Lifting and Jacking the Vehicle
(See: Maintenance/Vehicle Lifting/Service and Repair).
2. If the vehicle is crew cab, lower the fuel tank. Refer to Fuel Tank Replacement (See: Fuel
Delivery and Air Induction/Fuel Tank/Service and
Repair).
3. Remove the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner
Replacement (See: Body and Frame/Fender/Rear
Fender/Rear Fender Liner/Service and Repair).
4. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor
(1). 5. Pull upward in order to remove the sensor from the fuel tank module.
Installation Procedure
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1. Lightly lubricate the sensor seal with clean engine oil. 2. Press the sensor fully into the fuel tank
module. 3. Connect the chassis wiring harness electrical connector to the pressure sensor (1). 4.
Install the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner
Replacement (See: Body and Frame/Fender/Rear
Fender/Rear Fender Liner/Service and Repair).
5. If the vehicle is a crew cab, install the fuel tank. Refer to Fuel Tank Replacement (See: Fuel
Delivery and Air Induction/Fuel Tank/Service and
Repair).
6. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus >
Component Information > Diagrams > Diagram Information and Instructions
Information Bus: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Information Bus: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
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Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
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1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
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Component Information > Diagrams > Diagram Information and Instructions > Page 2976
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Component Information > Diagrams > Diagram Information and Instructions > Page 2977
Information Bus: Electrical Diagrams
Data Communication Schematics
Class 2 Serial Data
High Speed GMLAN Serial Data
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Information Bus: Description and Operation
Data Link Communications Description and Operation
Circuit Description
The data link connector (DLC) allows a scan tool to communicate with the class 2 serial data line.
The serial data line is the means by which the microprocessor-controlled modules in the vehicle
communicate with each other. Once the scan tool is connected to the class 2 serial data line
through the DLC, the scan tool can be used to monitor each module for diagnostic purposes and to
check for diagnostic trouble codes (DTCs). Class 2 serial data is transmitted on a single wire at an
average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to
carry data and depending on the message it may operate faster or slower. The bus will float at a
nominal 7 volts during normal operation. Each module can pull this lower during the transmission.
The bus is not at battery positive voltage or ground potential during normal operation. When the
ignition switch is in RUN, each module communicating on the class 2 serial data line sends a state
of health (SOH) message every 2 seconds to ensure that the module is operating properly. When a
module stops communicating on the class 2 serial data line, for example if the module loses power
or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other
modules on the class 2 serial data line, which expect to receive that SOH message, detect its
absence; those modules in turn set an internal DTC associated with the loss of SOH of the
non-communicating module. The DTC is unique to the module which is not communicating, for
example, when the inflatable restraint sensing and diagnostic module (SDM) SOH message
disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally
represent a failure of the module that set it.
Data Link Connector (DLC)
The data link connector (DLC) is a standardized 16-cavity connector. Connector design and
location is dictated by an industry wide standard, and is required to provide the following:
* Scan tool power battery positive voltage at terminal 16
* Scan tool power ground at terminal 4
* Class 2 serial data at terminal 2
* Common signal ground at terminal 5
Class 2 Serial Data Line
The class 2 serial data line on this vehicle is a combination ring-star configuration, where body
control module (BCM) is connected to multiple modules. Refer to Data Communication Schematics
(See: Diagrams/Electrical Diagrams). The following modules communicate on class 2 bus:
* The BCM
* The communication interface module (OnStar(R)), w/UE1
* The digital radio receiver (DRR), w/U2K
* The electronic brake control module (EBCM)
* The inflatable restraint sensing and diagnostic module (SDM)
* The instrument panel cluster (IPC)
* The powertrain control module (PCM)
* The radio
* The transfer case shift control module (TCSCM), w/4WD
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Information Bus: Initial Inspection and Diagnostic Overview
Diagnostic Starting Point - Data Communications
Diagnostic Starting Point - Data Communications
Begin the system diagnosis with Diagnostic System Check - Vehicle (See: Testing and
Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). The
Diagnostic System Check - Vehicle will provide the following information:
* The identification of the control modules which are not communicating
* The identification of any stored diagnostic trouble codes (DTCs) and their status
The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin
vehicle diagnosis. These must be performed before system DTC or symptom diagnosis.
Data Link References
Data Link References
This table identifies which serial data link that a particular module uses for in-vehicle data
transmission. Some modules may use more than one data link to communicate. Some modules
may have multiple communication circuits passing through them without actively communicating on
that data link. This table is used to assist in correcting a communication malfunction. For the
description and operation of these serial data communication circuits refer to Data Link
Communications Description and Operation (See: Description and Operation).
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Information Bus: Symptom Related Diagnostic Procedures
Symptoms - Data Communications
Symptoms - Data Communications
Important: The following steps must be completed before using the symptom tables.
1. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System
Check - Vehicle) before using the symptom tables in order to verify that all of the following are true:
* There are no DTCs set.
* The control modules can communicate via the serial data links.
2. Review the system operation in order to familiarize yourself with the system functions. Refer to
Data Link Communications Description and
Operation (See: Description and Operation).
Visual/Physical Inspection
* Inspect for aftermarket devices which could affect the operation of the systems. Refer to
Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General
Diagnostics).
* Inspect the easily accessible or visible system components for obvious damage or conditions
which could cause the symptom.
Intermittent
Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing
for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests
and General Diagnostics).
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
* Scan Tool Does Not Power Up (See: Scan Tool Does Not Power Up)
* Scan Tool Does Not Communicate with Class 2 Device (See: Scan Tool Does Not Communicate
with Class 2 Device)
* Scan Tool Does Not Communicate with High Speed GMLAN Device (See: Scan Tool Does Not
Communicate with High Speed GMLAN Device)
Scan Tool Does Not Communicate with Class 2 Device
Scan Tool Does Not Communicate with Class 2 Device
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Diagnostic Fault Information
Circuit/System Description
The serial data circuit is the means by which the control modules connected to it communicate with
each other. Once the scan tool is connected to the
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class 2 serial data circuit through the DLC, the scan tool can be used to monitor each control
module for diagnostic purposes and to check for diagnostic trouble codes (DTCs). Class 2 serial
data is transmitted on a single wire at an average of 10.4 Kbps. The bus is active at 7.0 volts
nominal and inactive at ground potential. When the ignition switch is in RUN, each control module
communicating on the class 2 serial data circuit sends a state of health (SOH) message to ensure
that the control module is operating properly. When a control module stops communicating on the
class 2 serial data circuit, for example if the control module loses power or ground, the SOH
message it normally sends on the data circuit disappears. Other control modules on the class 2
serial data circuit, which expect to receive that SOH message, detect its absence; those control
modules in turn set an internal DTC associated with the loss of SOH of the non-communicating
control module. The DTC is unique to the control module which is not communicating, for example,
when the body control module (BCM) SOH message disappears, several control modules set DTC
U1064. Note that a loss of serial data DTC does not normally represent a failure of the control
module that set it.
Diagnostic Aids
* Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a
history U-code present. However, there is no associated "current" or "active" status. Loss-ofcommunication U-codes such as these can set for a variety of reasons. Many times, they're
transparent to the vehicle operator and technician, and/or have no associated symptoms.
Eventually, they will erase themselves automatically after a number of fault-free ignition cycles.
This condition would most likely be attributed to one of these scenarios:
* A control module on the data communication circuit was disconnected while the communication
circuit is awake.
* Power to one or more modules was interrupted during diagnosis
* A low battery condition was present, so some control modules stop communicating when battery
voltage drops below a certain threshold.
* Battery power was restored to the vehicle and control modules on the communication circuit did
not all re-initialize at the same time.
* If a loss-of-communication U-code appears in history for no apparent reason, it is most likely
associated with one of the scenarios above. These are all temporary conditions and should never
be interpreted as an intermittent fault, causing you to replace a part.
* Do not replace a control module reporting a U-code. The U-code identifies which control module
needs to be diagnosed for a communication issue
* Communication may be available between the BCM and the scan tool with the low speed GMLAN
serial data system inoperative. This condition is due to the BCM using both the high and low speed
GMLAN systems.
* An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not
communicate with the vehicle. When the scan tool attempts to communicate with the vehicle a
message "no CANdi module detected" will be displayed.
* An open between the DLC and the BCM will only effect the communication with the scan tool.
The vehicle modules will still communicate, and the vehicle will start.
* The engine will not start when there is a total malfunction of the low speed GMLAN serial data
circuit.
* Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble
Codes (DTC) and no low speed LAN communications with the scan tool. These conditions may be
caused by the installation of an aftermarket navigation radio module (see bulletins). Some
customers may comment of one or more of the following concerns:
* Vehicle will not crank.
* Vehicle cranks but will not start.
* Vehicle stability enhancement system warning lights and messages.
* PRNDL gear indicator position errors.
* Tire Pressure Monitor (TPM) system warning lights.
Reference Information Schematic Reference
Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View
Reference
Component Connector End Views (See: Diagrams/Connector Views) Description and Operation
Data Link Communications Description and Operation (See: Description and Operation) Electrical
Information Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Circuit/System Testing
Note: Use the schematic to identify the following:
* Control modules the vehicle is equipped with
* Control module locations on the class 2 serial data circuit
* The class 2 serial data circuit terminals for each control module
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2984
1. Attempt to communicate with all control modules on the class 2 serial data circuit, refer to Data
Link References (See: Initial Inspection and
Diagnostic Overview/Data Link References). Communications should not be available with two or
more control modules on the class 2 serial data circuit.
‹› If only one control module is not communicating, diagnose that control module only; refer to DTC
U1001-U1254 (See: Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1001).
‹› If one or more control modules are communicating but not all, refer to Testing the Serial Data
Circuit for an Open/High Resistance.
2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3.
All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground
circuit terminal 5 and ground.
‹› If greater than the specified range, test the ground circuit for an open/high resistance.
4. Ignition ON, test for less than 4.5 V between the serial data circuit terminal 2 and ground.
‹› If greater than the specified range, test the serial data circuit for a short to voltage; refer to
Testing the Serial Data Circuit for a Short to
Voltage.
5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuit
terminal 2 and ground.
‹› If less than the specified range, test the serial data circuit for a short to ground; refer to Testing
the Serial Data Circuit for a Short to ground.
6. Disconnect the appropriate harness connector at the BCM. 7. Test for less than 2 ohm between
the DLC serial data circuit terminal 2 and the BCM connector.
‹› If greater than the specified range, test the serial data circuit for an open/high resistance. If the
circuits test normal, replace the BCM.
Testing the Serial Data Circuits for a Short to Voltage
1. Ignition OFF, disconnect the appropriate harness connectors at the BCM. 2. Ignition ON, test for
less than 4.5 V between the DLC serial data circuit terminal 2 and ground.
‹› If greater than the specified range, repair the short to voltage.
3. Test for less than 4.5 V between each serial data circuit at the BCM connectors and ground.
‹› If greater than the specified range, perform the appropriate test listed below:
* Serial data circuits with one control module, test the serial data circuit for a short to voltage. If the
circuit tests normal, replace the control module.
* Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a
short to voltage. If the circuits test normal, replace the control module that causes the short to
voltage when connected.
Testing the Serial Data Circuits for a Short to Ground
1. Ignition OFF, disconnect the appropriate harness connectors at the BCM. 2. Test for infinite
resistance between the DLC serial data circuit terminal 2 and ground.
‹› If not the specified value, repair the short to ground.
3. Ignition OFF for 60 seconds, test for greater than 100 ohm between each serial data circuit at
the BCM connectors and ground.
‹› If less than the specified range, perform the appropriate test listed below:
* Serial data circuits with one control module, test the serial data circuit for a short to ground. If the
circuit tests normal, replace the control module.
* Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a
short to voltage. If the circuits test normal, replace the control module that causes the short to
ground when connected.
Testing the Serial Data Circuit for an Open/High Resistance
1. Ignition OFF, disconnect the appropriate harness connectors at the BCM. 2. Install a 3A fused
jumper wire between the disconnected BCM connector DLC terminal and a class 2 serial data
circuit that is not communicating. 3. Ignition ON, verify the scan tool communicates with the control
modules connected to the class 2 serial data circuit.
‹› If any control module does not communicate, test each section of the serial data circuit for an
open/high resistance. If the circuits test normal,
replace the control module that does not communicate when connected.
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2985
Repair Instructions
Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair.
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Control Module References (See: Testing and Inspection/Programming and Relearning) for
module replacement, setup, and programming
Scan Tool Does Not Communicate with High Speed GMLAN Device
Scan Tool Does Not Communicate with High Speed GMLAN Device
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Diagnostic Fault Information
Circuit/System Description
The serial data is transmitted on two twisted wires that allow speeds up to 500 Kb/s. The twisted
pair is terminated with two 120 ohms resistors, one is internal to the engine control module (ECM)
and the other can be a separate resistor in a connector assembly or in another control module. The
resistors are used as the load for the High Speed GMLAN buss during normal vehicle operation.
The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high
speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level of
approximately 2.5 V. Driving the lines to their extremes, adds one volt to the high speed GMLAN
serial data bus (+) circuit and subtracts one volt from the high speed GMLAN serial data bus (-)
circuit. If serial data is lost, control modules will set a no communication code against the
non-communicating control module. Note that a loss of serial data DTC does not represent a failure
of the module that set it.
Diagnostic Aids
* Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a
history U-code present. However, there is no associated "current" or "active" status. Loss-ofcommunication U-codes such as these can set for a variety of reasons. Many times, they're
transparent to the vehicle operator and technician, and/or have no associated symptoms.
Eventually, they will erase themselves automatically after a number of fault-free ignition cycles.
This condition would most likely be attributed to one of these scenarios:
- A control module on the data communication circuit was disconnected while the communication
circuit is awake.
- Power to one or more modules was interrupted during diagnosis
- A low battery condition was present, so some control modules stop communicating when battery
voltage drops below a certain threshold.
- Battery power was restored to the vehicle and control modules on the communication circuit did
not all re-initialize at the same time.
- If a loss-of-communication U-code appears in history for no apparent reason, it is most likely
associated with one of the scenarios above. These are all temporary conditions and should never
be interpreted as an intermittent fault, causing you to replace a part.
* Do not replace a control module reporting a U code. The U code identifies which control module
needs to be diagnosed for a communication issue.
* Communication may be available between the BCM and the scan tool with the high speed
GMLAN serial data system inoperative. This condition is due to the BCM using both the high and
low speed GMLAN systems.
* An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not
communicate with the vehicle. When the scan tool
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attempts to communicate with the vehicle a message "no CANdi module detected" will be
displayed.
* The engine will not start when there is a total malfunction of the high speed GMLAN serial data
bus.
* Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble
Codes (DTC) and no low speed GMLAN communications with the scan tool.
* The engine will not start when there is a total malfunction of the high speed GMLAN serial data
bus. These conditions may be caused by the installation of an aftermarket navigation radio module
(see bulletins). Some customers may comment of one or more of the following concerns:
- Vehicle will not crank.
- Vehicle cranks but will not start.
- Vehicle stability enhancement system warning lights and messages.
- PRNDL gear indicator position errors.
- Tire Pressure Monitor (TPM) system warning lights.
Reference Information Schematic Reference
* Data Communication Schematics (See: Diagrams/Electrical Diagrams)
* Control Module References (See: Testing and Inspection/Programming and Relearning)
Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Description and Operation
Data Link Communications Description and Operation (See: Description and Operation) Electrical
Information Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning) for scan
tool information
Circuit/System Testing
Note: Each control module may need to be disconnected to isolate a circuit fault. Use the
schematic to identify the following:
* Control modules the vehicle is equipped with
* High speed GMLAN serial data circuit terminating resistors
* Control module locations on the high speed GMLAN serial data circuits
* Each control module's high speed GMLAN serial data circuit terminals
1. Attempt to communicate with all control modules on the high speed GMLAN serial data circuit,
refer to Data Link References (See: Initial
Inspection and Diagnostic Overview/Data Link References). Communications should not be
available with two or more control modules on the high speed GMLAN serial data circuit.
‹› If only one control module is not communicating, diagnose that control module only; refer to DTC
U0100-U0299 (See: Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100).
2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3.
All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground
circuit terminal 5 and ground.
‹› If greater than the specified range, test the ground circuit for an open/high resistance.
4. Ignition ON, test for less than 4.5 V between the serial data circuits listed below and ground:
* Terminal 6
* Terminal 14
‹› If greater than the specified range, test the serial data circuit for a short to voltage; refer to
Testing the Serial Data Circuits for a Short to
Voltage.
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5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuits listed
below and ground:
* Terminal 6
* Terminal 14
‹› If not the specified value, test the serial data circuit for a short to ground; refer to Testing the
Serial Data Circuits for a Short to ground.
6. Test for 50-70 ohm between the serial data circuits terminal 6 and terminal 14.
‹› If less than 35 ohm, test for a short between the serial data circuits; refer to Testing the Serial
Data Circuits for a Short between the Circuits. ‹› If 35-50 ohm there may be a third terminating
resistor between the serial data circuits. This can happen if the incorrect control module is
installed. Some control modules are available with and without the terminating resistors installed to
reduce the need of terminating resistors in the wiring harness.
‹› If greater than 70 ohm but less than infinite, test the serial data circuit for an open/high
resistance; refer to Testing the Serial Data Circuits for
an Open/High Resistance.
‹› If infinite, test the serial data circuits between the DLC and the first connection to the serial data
circuit for an open/high resistance.
Testing the Serial Data Circuits for a Short to Voltage
1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits
at an easily accessible control module. 2. Ignition ON, test for greater than 4.5 V between each
serial data circuit at the control module connector that was just disconnected and ground.
Verify that one or more serial data circuits are greater than 4.5 V.
‹› If all serial data circuits are less than the specified range, replace the control module that was
disconnected.
3. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits
at another control module, in the direction of the
circuit shorted to voltage.
4. Ignition ON, test for greater than 4.5 V between the serial data circuits at the control module
connector that was just disconnected and ground.
Verify that one or more serial data circuits are greater than 4.5 V.
‹› If all serial data circuits are less than the specified range, replace the control module that was
just disconnected.
5. Repeat step 3 until one of the follow conditions are isolated:
* A short to voltage on the serial data circuit between 2 control modules
* A short to voltage on the serial data circuit between a control module and a terminating resistor.
Testing the Serial Data Circuits for a Short to Ground
1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits
at an easily accessible control module. 2. Ignition OFF for 60 seconds, test for less than 1k ohm
between each serial data circuit at the control module connector that was just disconnected
and ground. Verify that one or more serial data circuits are less than 1k ohm.
‹› If all serial data circuits are greater than the specified range, replace the control module that was
disconnected.
3. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another
control module, in the direction of the circuit
shorted to ground.
4. Ignition OFF for 60 seconds, test for less than 1k ohm between the serial data circuits at the
control module connector that was just disconnected
and ground. Verify that one or more serial data circuits are less than 1k ohm.
‹› If greater than the specified range for all serial data circuits, replace the control module that was
just disconnected.
5. Repeat step 3 until one of the follow conditions are isolated:
* A short to ground on the serial data circuit between 2 control modules
* A short to ground on the serial data circuit between a control module and a terminating resistor.
Testing the Serial Data Circuits for a Short between the Circuits
1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits
at an easily accessible control module that is not
communicating.
2. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at
the control module connector that was just
disconnected. Verify that one pair of serial data circuits are less than 35 ohm.
‹› If each pair of serial data circuits is greater than the specified range, replace the control module
that was disconnected.
3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the
harness connectors with the high speed GMLAN serial data circuits at another control module, in
the direction of the circuits
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shorted together.
5. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at
the control module connector that was just
disconnected. Verify that one pair of serial data circuits are less than 35 ohm.
‹› If each pair of serial data circuits is within the specified range, replace the control module that
was just disconnected.
6. Repeat step 3 until one of the following conditions are isolated:
* Serial data circuits shorted together between 2 control modules
* Serial data circuits shorted together between a control module and a terminating resistor
* A shorted terminating resistor
Testing the Serial Data Circuits for an Open/High Resistance
1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits
at an easily accessible control module that is not
communicating.
2. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data
circuits at the control module connector that was just
disconnected. Verify that one pair of serial data circuits are greater than 100k ohm.
‹› If each pair of serial data circuits is less than the specified range, replace the control module that
was disconnected.
3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the
harness connectors with the high speed GMLAN serial data circuits at another control module, in
the direction of the open circuit. 5. Ignition OFF for 60 seconds, test for greater than 100k ohm
between each pair of serial data circuits at the control module connector that was just
disconnected. Verify that one pair of serial data circuits are greater than 100k ohm.
‹› If each pair of serial data circuits is less than the specified range, replace the control module that
was just disconnected.
6. Repeat step 3 until one of the following conditions are isolated:
* An open/high resistance on the serial data circuit between 2 control modules
* An open/high resistance on the serial data circuit between a control module and a terminating
resistor
* An open/high resistance terminating resistor
Repair Instructions
Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair.
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Control Module References (See: Testing and Inspection/Programming and Relearning) for
control module replacement, setup, and programming
Scan Tool Does Not Power Up
Scan Tool Does Not Power Up
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Diagnostic Fault Information
Circuit/System Description
The data link connector (DLC) is a standardized 16 cavity connector. Connector design and
location is dictated by an industry wide standard, and is
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required to provide the following:
* Scan tool power battery positive voltage at terminal 16
* Scan tool power ground at terminal 4
* Common signal ground at terminal 5
Diagnostic Aids
* The scan tool will power up with the ignition OFF. Some modules however, will not communicate
unless the ignition is ON and the power mode master (PMM) module sends the appropriate power
mode message.
* If the battery positive voltage, ground circuits and connections of the DLC are functioning
properly, the malfunction must be due to the scan tool/CANdi module.
Reference Information Schematic Reference
Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View
Reference
Component Connector End Views (See: Diagrams/Connector Views) Description and Operation
Data Link Communications Description and Operation (See: Description and Operation) Electrical
Information Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning) for scan
tool information
Circuit/System Testing
1. Ignition ON, test for battery voltage between the battery positive voltage circuit of the DLC and
ground.
‹› If less than battery voltage, test the voltage supply circuit for a short to ground or an open/high
resistance.
2. Test for less than 1.0 ohm between the ground circuit of the DLC and ground.
‹› If greater than the specified range, test the ground circuit for an open/high resistance.
3. If all tests normal, refer to the scan tool/CANdi module user guide.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Engine - Right Side (LH8)
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1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
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Knock Sensor: Diagrams
Component Connector End Views
Knock Sensor (KS) 1 (LH8)
Knock Sensor (KS) 2 (LH8)
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Service and Repair > Knock Sensor 1 Replacement
Knock Sensor: Service and Repair Knock Sensor 1 Replacement
Knock Sensor 1 Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS
retaining bolt. 4. Remove the KS (2) from the engine block.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
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1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals
down.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle.
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Knock Sensor: Service and Repair Knock Sensor 2 Replacement
Knock Sensor 2 Replacement
Removal Procedure
1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS)
through the wheelhouse. Refer to Lifting and Jacking
the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair).
2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body
and Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS
retaining bolt. 5. Remove the KS (1) from the engine block.
Installation Procedure
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Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals
rearward.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left
wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and
Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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System) > Component Information > Locations > Page 3004
Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test).
Reference Information Schematic Reference
Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning) for scan
tool information Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
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System) > Component Information > Locations > Page 3005
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or
replace the battery positive cable to the underhood fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
‹› If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
‹› If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal,
and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM
for a short to ground. If the circuit tests normal, replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming
and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and
Inspection/Programming and Relearning)
* Engine Control Module Replacement (See: Engine Control Module/Service and Repair)
* Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power
Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay
Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution
Relay/Service and Repair/Relay Replacement (Within an Electrical Center))
Repair Verification
1. Install any components that have been removed or replaced during diagnosis.
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System) > Component Information > Locations > Page 3006
2. Perform any adjustment, programming, or setup procedures that are required when a
component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60
seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while
observing the powertrain relay circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing
and Inspection/Diagnostic Trouble Code
Descriptions) and perform the appropriate diagnostic procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Component Information > Testing and Inspection
Malfunction Indicator Lamp: Testing and Inspection
Malfunction Indicator Lamp (MIL) Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category.
Circuit/System Description
Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module
(ECM) turns the MIL ON by grounding the MIL control circuit.
Reference Information Schematic Reference
* Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges
and Warning Indicators/System Diagram/Instrument Cluster Schematics)
* Engine Controls Schematics (See: Diagrams/Electrical Diagrams)
Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning)for scan
tool information
Circuit/System Verification
Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool.
Circuit/System Testing
1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition
ON, verify that a test lamp illuminates between the ignition circuit and ground.
‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high
resistance. If the circuit tests normal and the
ignition circuit fuse is open, replace the IPC.
3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON
and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the
commanded states.
‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests
normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to
voltage or an open/high resistance. If the circuit tests normal, replace the
ECM.
5. If all circuits test normal, replace the IPC.
Repair Instructions
Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/Verification Tests and Procedures) after completing the
diagnostic procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Component Information > Testing and Inspection > Page 3010
* Instrument Cluster Replacement (See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement)
* Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM
replacement, setup, and programming
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Powertrain Component Views
Engine - Right Side (LH8)
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Page 3014
Manifold Pressure/Vacuum Sensor: Diagrams
Component Connector End Views
Manifold Absolute Pressure (MAP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Page 3015
Manifold Pressure/Vacuum Sensor: Service and Repair
Manifold Absolute Pressure Sensor Replacement
Removal Procedure
1. Remove the upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute
pressure (MAP) sensor.
3. Remove the MAP sensor retainer (1) from the intake manifold. 4. Remove the MAP sensor (2)
from the intake manifold.
Installation Procedure
Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Page 3016
1. Install the MAP sensor (2) into the intake manifold. 2. Install the MAP sensor retainer (2) to the
intake manifold.
3. Connect the engine wiring harness electrical connector (3) to the MAP sensor. 4. Install the
upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor >
Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Special Tools
J 41712 Oil Pressure Switch Socket
Removal Procedure
1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and
Repair).
2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor.
3. If not equipped with active fuel management perform the following step, using J 41712 or
equivalent, remove the oil pressure sensor (706) and
washer (707).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor >
Component Information > Service and Repair > Page 3020
4. If equipped with active fuel management perform the following step, using J 41712 or equivalent,
remove the oil pressure sensor (706) and
washer (707).
Installation Procedure
1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids,
Lubricants, and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. If equipped with active fuel management perform the following step, using J 41712 or equivalent.
Install the oil pressure sensor (706) and washer
(707). Tighten the sensor to 35 Nm (26 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor >
Component Information > Service and Repair > Page 3021
3. If not equipped with active fuel management, perform the following step, using J 41712 or
equivalent. Install the oil pressure sensor (706) and
washer (707).
4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the
sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement
(See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Locations
Oxygen Sensor: Locations
Powertrain Component Views
Rear of the Transmission Components
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Locations > Page 3025
Oxygen Sensor: Diagrams
Component Connector End Views
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 (LH8)
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Locations > Page 3026
Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (LH8)
Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Locations > Page 3027
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution
Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution
Excessive Force and Oxygen Sensor Caution
Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 3030
Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution
Heated Oxygen and Oxygen Sensor Caution
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 3031
Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution
Heated Oxygen Sensor Resistance Learn Reset Caution
Caution: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 3032
Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution
Silicon Contamination of Heated Oxygen Sensors Caution
Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4)
from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the
rear HO2S electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3035
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
4. Remove the HO2S (1).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3036
2. Install the HO2S (1).
Tighten the sensor to 42 Nm (31 lb ft).
3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S
electrical connector (4) to the engine wiring harness electrical connector (1). 5. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3037
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2)
from the engine wiring harness electrical connector (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3038
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
3. Remove the HO2S (2).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3039
2. Install the HO2S (2).
Tighten the sensor to 42 Nm (31 lb ft).
3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the
HO2S electrical connector (2) to the engine wiring harness electrical connector (3). 5. Lower the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3040
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1
Heated Oxygen Sensor Replacement - Bank 2 Sensor 1
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2)
from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the
rear HO2S electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3041
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
4. Remove the HO2S (1).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3042
2. Install the HO2S (1).
Tighten the sensor to 42 Nm (31 lb ft).
3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S
electrical connector (2) to the engine wiring harness electrical connector (1). 5. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3043
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2
Heated Oxygen Sensor Replacement - Bank 2 Sensor 2
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4)
from the engine wiring harness electrical connector (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3044
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
3. Remove the HO2S (2).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3045
2. Install the HO2S (2).
Tighten the sensor to 42 Nm (31 lb ft).
3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the
HO2S electrical connector (4) to the engine wiring harness electrical connector (3). 5. Lower the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins >
Customer Interest for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start Up
Body Control Module: Customer Interest Body Controls - Security Lamp ON After Start Up
TECHNICAL
Bulletin No.: 09-08-56-001
Date: March 12, 2009
Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs
(Reprogram BCM)
Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T
Note
The information contained in this bulletin applies to vehicles located in the U.S. only.
Condition
Some customers may comment that the Security Light remains illuminated after the vehicle has
started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and
Engine Control Module (ECM).
Cause
This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run"
and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM
sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the
"Crank" mode to turn the light off.
Correction
Important Do Not replace the ignition switch for this concern.
1. Verify the customer concern.
2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI.
3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the
latest software available on TIS2WEB. Refer to the
Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with
the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After
Start Up
Body Control Module: All Technical Service Bulletins Body Controls - Security Lamp ON After Start
Up
TECHNICAL
Bulletin No.: 09-08-56-001
Date: March 12, 2009
Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs
(Reprogram BCM)
Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T
Note
The information contained in this bulletin applies to vehicles located in the U.S. only.
Condition
Some customers may comment that the Security Light remains illuminated after the vehicle has
started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and
Engine Control Module (ECM).
Cause
This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run"
and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM
sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the
"Crank" mode to turn the light off.
Correction
Important Do Not replace the ignition switch for this concern.
1. Verify the customer concern.
2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI.
3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the
latest software available on TIS2WEB. Refer to the
Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with
the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views
Body Control Module: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
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17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver
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15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
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4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210
(A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control
Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to
Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
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Page 3065
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
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25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Page 3067
Body Control Module: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Right Kick Panel Components
1 - Body Harness 2 - Instrument Panel Harness 3 - Body Control Module (BCM) 4 - X201 5 - Body
Control Module (BCM) X2 6 - Body Control Module (BCM) X1
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Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
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Body Control Module (BCM) X2
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Body Control Module: Service and Repair
Body Control Module Replacement
Removal Procedure
Important:
* The ignition switch should be in the OFF position when connecting or disconnecting the
connectors to the body control module (BCM).
* Always disconnect the black body wiring harness connector FIRST and the gray instrument panel
(I/P) wiring harness connector LAST.
* Always connect the black body wiring harness connector FIRST and the gray I/P wiring harness
LAST.
* Do not open the BCM housing. The module does not have any serviceable components. The
module may be replaced only as an assembly.
1. Ensure the ignition switch is in the OFF position. 2. Remove the right front hinge pillar trim panel.
Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
3. Disconnect the body wiring harness electrical connector (1) from the BCM.
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4. Disconnect the I/P wiring harness electrical connector (1) from the BCM.
5. Release the fastener retaining the body wiring harness electrical connector to the BCM.
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6. Remove the 2 fasteners retaining the BCM to the hinge pillar. 7. Remove the BCM from the
hinge pillar by unlocking the integral tab. 8. Remove the BCM from the vehicle.
Installation Procedure
1. Position the BCM to the vehicle. 2. Attach the BCM to the hinge pillar with the integral tab. 3.
Install the 2 fasteners retaining the BCM to the hinge pillar.
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4. Install the fastener retaining the body wiring harness electrical connector to the BCM.
5. Connect the body wiring harness electrical connector (1) to the BCM.
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6. Connect the I/P wiring harness electrical connector (1) to the BCM. 7. Install the right front hinge
pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and
Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
8. If installing a replacement BCM, program the BCM. Refer to Control Module References (See:
Testing and Inspection/Programming and
Relearning).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - Aftermarket Accessory Usage
Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory
Usage
INFORMATION
Bulletin No.: 04-06-04-054B
Date: November 18, 2010
Subject: Info - Non-GM Parts and Accessories (Aftermarket)
Models:
2011 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed
Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate
Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System).
The recent rise and expansion of companies selling non-GM parts and accessories has made it
necessary to issue this reminder to dealers regarding GM's policy on the use and installation of
these aftermarket components.
When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to
use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs,
special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the
same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty
repairs, special policy repairs or any repairs paid for by GM.
During a warranty repair, if a GM original equipment part is not available through GM Customer
Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources,
the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order
the circumstances surrounding why non-GM parts were used. The dealer must give customers
written notice, prior to the sale or service, that such parts or accessories are not marketed or
warranted by General Motors.
It should also be noted that dealers modifying new vehicles and installing equipment, parts and
accessories obtained from sources not authorized by GM are responsible for complying with the
National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed
by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design
characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully
understand that non-GM approved parts may not have been validated, tested or certified for use.
This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part
failure occurs as the result of the installation or use of a non-GM approved part, the warranty will
not be honored.
A good example of non-authorized modification of vehicles is the result of an ever increasing
supply of aftermarket devices available to the customer, which claim to increase the horsepower
and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to
one or more of the following modifications:
- Propane injection
- Nitrous oxide injection
- Additional modules (black boxes) that connect to the vehicle wiring systems
- Revised engine calibrations downloaded for the engine control module
- Calibration modules which connect to the vehicle diagnostic connector
- Modification to the engine turbocharger waste gate
Although the installation of these devices, or modification of vehicle components, can increase
engine horsepower and torque, they may also negatively affect the engine emissions, reliability
and/or durability. In addition, other powertrain components, such as transmissions, universal joints,
drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the
installation of these devices.
General Motors does not support or endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or
06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for
calibration verification.
These same policies apply as they relate to the use of non-GM accessories. Damage or failure
from the use or installation of a non-GM accessory will not be covered under warranty. Failure
resulting from the alteration or modification of the vehicle, including the cutting, welding or
disconnecting of the vehicle's original equipment parts and components will void the warranty.
Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal
inquiry at either the local, state or federal level that
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Controls - Aftermarket Accessory Usage > Page 3081
results from the alteration or modification of a vehicle using non-GM approved parts or accessories.
Dealers should be especially cautious of accessory companies that claim the installation of their
product will not void the factory warranty. Many times these companies have even given direction
on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from
finding out that is has been installed.
Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada
by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair
is to be made on the vehicle, even with the installation of such non-GM approved components, the
customer is to be made aware of General Motors position on this issue and is to sign the
appropriate goodwill documentation required by General Motors.
It is imperative for dealers to understand that by installing such devices, they are jeopardizing not
only the warranty coverage, but also the performance and reliability of the customer's vehicle.
Disclaimer
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Controls - Aftermarket Accessory Usage > Page 3082
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
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Controls - Aftermarket Accessory Usage > Page 3083
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
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Controls - Aftermarket Accessory Usage > Page 3084
2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
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Controls - Aftermarket Accessory Usage > Page 3085
Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - Aftermarket Accessory Usage > Page 3086
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026B
Date: April 07, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2010 model year and information about
retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number
09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle)
to stresses that were not tested by General Motors. It is because of these unknown stresses, and
the potential to alter reliability, durability and emissions performance, that GM has adopted a policy
that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty
coverage, to the powertrain and driveline components whenever the presence of a non-GM
(aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
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Controls - Aftermarket Accessory Usage > Page 3087
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
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Controls - Aftermarket Accessory Usage > Page 3088
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the
complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
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Controls - Aftermarket Accessory Usage > Page 3089
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views
Engine Control Module: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
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> Page 3092
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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> Page 3093
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C
Refrigerant Pressure Sensor (C60)
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> Page 3094
Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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> Page 3095
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Rear of the Engine Compartment Components - 1 of 2
1 - Engine Control Module (ECM) 2 - Front Plenum Panel
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Engine Control Module: Diagrams
Component Connector End Views
Engine Control Module (ECM) X1
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Engine Control Module (ECM) X2
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Engine Control Module (ECM) X3
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Engine Control Module: Description and Operation
Engine Control Module Description
The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent
driveability and fuel economy. The engine control module (ECM) is the control center of this
system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors
the information from various sensors and other inputs, and controls the systems that affect vehicle
performance and emissions. The ECM also performs the diagnostic tests on various parts of the
system. The ECM can recognize operational problems and alert the driver via the malfunction
indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble
code (DTC). The problem area is identified by the particular DTC that is set. The control module
supplies a buffered voltage to various sensors and switches. Review the components and wiring
diagrams in order to determine which systems are controlled by the ECM.
Malfunction Indicator Lamp (MIL) Operation
The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display
as either SERVICE ENGINE SOON or one of the following symbols when commanded ON:
The MIL indicates that an emissions related fault has occurred and vehicle service is required.
The following is a list of the modes of operation for the MIL:
* The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to
ensure the MIL is able to illuminate.
* The MIL turns OFF after the engine is started if a diagnostic fault is not present.
* The MIL remains illuminated after the engine is started if the control module detects a fault. A
diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an
emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test
Passed has been reported for the diagnostic test that originally caused the MIL to illuminate.
* The MIL flashes if the control module detects a misfire condition which could damage the catalytic
converter.
* When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the
ignition is ON.
* When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition
is cycled OFF and then ON.
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Engine Control Module: Service and Repair
Engine Control Module Replacement
Service of the engine control module (ECM) should normally consist of either replacement of the
ECM or electrically erasable programmable read only memory (EEPROM) programming. If the
diagnostic procedures call for the ECM to be replaced, the ECM should be inspected first to see if
the correct part is being used. If the correct part is being used, remove the faulty ECM and install
the new service ECM.
Caution:
* Turn the ignition OFF when installing or removing the control module connectors and
disconnecting or reconnecting the power to the control module (battery cable, powertrain control
module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control
module fuse, jumper cables, etc.) in order to prevent internal control module damage.
* Control module damage may result when the metal case contacts battery voltage. DO NOT
contact the control module metal case with battery voltage when servicing a control module, using
battery booster cables, or when charging the vehicle battery.
* In order to prevent any possible electrostatic discharge damage to the control module, do no
touch the connector pins or the soldered components on the circuit board.
* Remove any debris from around the control module connector surfaces before servicing the
control module. Inspect the control module connector gaskets when diagnosing or replacing the
control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant
intrusion into the control module.
* The replacement control module must be programmed.
Note: It is necessary to record the remaining engine oil life. If the replacement module is not
programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the
replacement module is not programmed with the remaining engine oil life, the engine oil will need
to be changed at 5 000 km (3,000 mi) from the last engine oil change.
Removal Procedure
1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine
oil life. 2. Remove the windshield washer solvent container. Refer to Windshield Washer Solvent
Container Replacement (See: Wiper and Washer
Systems/Windshield Washer Reservoir/Service and Repair).
3. Disengage the integral connector position assurance (CPA) retainer (1) on the body wiring
harness electrical connector. 4. Disconnect the body wiring harness electrical connector (2) from
the ECM.
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5. Disengage the integral CPA retainers on the engine wiring harness electrical connectors. 6.
Disconnect the engine wiring harness electrical connectors (2) from the ECM.
7. Lift up the ECM bracket tabs (2) and tilt the ECM (1) towards the front of the vehicle, removing
the ECM (1).
Installation Procedure
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1. Set the bottom of the ECM (1) into the bracket, and push the top of the ECM against the bracket.
Ensure that the tabs (2) secure the ECM (1).
2. Connect the engine wiring harness electrical connectors (2) to the ECM. 3. Engage the integral
CPA retainers on the engine wiring harness electrical connectors.
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4. Connect the body wiring harness electrical connector (2) to the ECM. 5. Engage the integral
CPA retainer (1) on the body wiring harness electrical connector. 6. If a NEW ECM was installed,
the ECM must be programmed. Refer to Control Module References (See: Testing and
Inspection/Programming
and Relearning).
7. Install the windshield washer solvent container. Refer to Windshield Washer Solvent Container
Replacement (See: Wiper and Washer
Systems/Windshield Washer Reservoir/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
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Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test).
Reference Information Schematic Reference
Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning) for scan
tool information Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
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* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or
replace the battery positive cable to the underhood fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
‹› If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
‹› If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal,
and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM
for a short to ground. If the circuit tests normal, replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming
and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and
Inspection/Programming and Relearning)
* Engine Control Module Replacement (See: Engine Control Module/Service and Repair)
* Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power
Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay
Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution
Relay/Service and Repair/Relay Replacement (Within an Electrical Center))
Repair Verification
1. Install any components that have been removed or replaced during diagnosis.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3113
2. Perform any adjustment, programming, or setup procedures that are required when a
component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60
seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while
observing the powertrain relay circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing
and Inspection/Diagnostic Trouble Code
Descriptions) and perform the appropriate diagnostic procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument
Panel/Center Console Component Views
Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Behind the Left Side of the I/P Components
1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal
Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition
Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument
Panel/Center Console Component Views > Page 3119
Accelerator Pedal Position Sensor: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument
Panel/Center Console Component Views > Page 3120
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument
Panel/Center Console Component Views > Page 3121
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner -
Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument
Panel/Center Console Component Views > Page 3122
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument
Panel/Center Console Component Views > Page 3123
25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to
Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to
Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33
- Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3124
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3125
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP
sensor nuts. 3. Remove the APP sensor from the vehicle.
Installation Procedure
1. Position the APP sensor over the studs.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3126
2. Install the APP sensor nuts.
Tighten the APP sensor mounting nuts to 9 Nm (80 lb in).
3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure
full range of motion.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams
Air Flow Meter/Sensor: Diagrams
Component Connector End Views
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3130
Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Removal Procedure
Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not
dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do
not touch the sensing elements or allow anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct
only, to aid in installation.
1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor.
2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner
upper housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3131
Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The
arrow must point toward the engine.
1. Install the MAF/IAT sensor (2) to the air cleaner upper housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the MAF/IAT sensor screws (1).
Tighten the screws to 1.5 Nm (13 lb in).
3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Engine - Front (LH8)
1 - Throttle Body 2 - Camshaft Position (CMP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3135
Camshaft Position Sensor: Diagrams
Component Connector End Views
Camshaft Position (CMP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3136
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Page 3140
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Page 3141
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining
and Filling (Static Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See:
Engine, Cooling and Exhaust/Cooling System/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant
temperature (ECT) sensor.
3. Remove the ECT sensor (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Page 3142
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent. 2. Install the ECT sensor (1).
Tighten the sensor to 20 Nm (15 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the
cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Page 3143
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Powertrain Component Views
Engine - Right Side (LH8) (5.3L)
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3147
Crankshaft Position Sensor: Diagrams
Component Connector End Views
Crankshaft Position (CKP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair >
Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and
Charging/Starting System/Starter Motor/Service and
Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP)
sensor.
3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the
engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair >
Crankshaft Position Sensor Replacement > Page 3150
1. Install the CKP sensor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the CKP sensor bolt.
Tighten the bolt to 25 Nm (18 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the
starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting
System/Starter Motor/Service and Repair
)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position
System Variation Learn (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair >
Crankshaft Position Sensor Replacement > Page 3151
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for the
applicable DTC that set.
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P
Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle
(See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that
set.
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams
Fuel Level Sensor: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 3155
Fuel Level Sensor: Service and Repair
Fuel Level Sensor Replacement
Removal Procedure
1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel
Delivery and Air Induction/Fuel Pump/Service and
Repair).
2. Disconnect the fuel level sensor electrical connector (1) from the module cover.
3. Complete the following in order to remove the fuel level sensor (1) from the module bucket:
1. Disengage the locking tabs on the sensor. 2. Slide the sensor upward from the bucket.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 3156
1. Complete the following in order to install the fuel level sensor to the module bucket.
1. Align the edges of the sensor with the slots in the module bucket. 2. Slide the sensor down into
position, ensure the locking tabs are fully engaged.
2. Connect the fuel level sensor electrical connector (1) to the module cover. 3. Install the fuel tank
module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air
Induction/Fuel Pump/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's
P0451/P0454 Set
Fuel Tank Pressure Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0451/P0454 Set
TECHNICAL
Bulletin No.: 10-06-04-001C
Date: December 08, 2010
Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure
Sensor Cover)
Models:
2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to
November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to
November 4, 2009) 2009-2010 Pontiac G5
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System).
Condition
Some customers may comment on a check engine light. Upon further investigation, a technician
may find one of the above DTCs.
Cause
This condition may be caused by normal water accumulation or condensation blocking the air
reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If
the signal varies during an Engine Off Natural Vacuum test, a false DTC could set.
Correction
Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI
diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield,
P/N 20893611. Clear the DTCs.
Chevrolet Colorado, Silverado and GMC Canyon, Sierra
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable
adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank
straps. 5. Lower the fuel tank halfway.
6. Locate the fuel tank pressure sensor (1).
7. Install the fuel tank pressure sensor cover, GM P/N 20893611.
Chevrolet Cobalt and Pontiac G5
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's
P0451/P0454 Set > Page 3165
2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's
P0451/P0454 Set
Fuel Tank Pressure Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's
P0451/P0454 Set
TECHNICAL
Bulletin No.: 10-06-04-001C
Date: December 08, 2010
Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure
Sensor Cover)
Models:
2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to
November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to
November 4, 2009) 2009-2010 Pontiac G5
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System).
Condition
Some customers may comment on a check engine light. Upon further investigation, a technician
may find one of the above DTCs.
Cause
This condition may be caused by normal water accumulation or condensation blocking the air
reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If
the signal varies during an Engine Off Natural Vacuum test, a false DTC could set.
Correction
Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI
diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield,
P/N 20893611. Clear the DTCs.
Chevrolet Colorado, Silverado and GMC Canyon, Sierra
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable
adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank
straps. 5. Lower the fuel tank halfway.
6. Locate the fuel tank pressure sensor (1).
7. Install the fuel tank pressure sensor cover, GM P/N 20893611.
Chevrolet Cobalt and Pontiac G5
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's
P0451/P0454 Set > Page 3171
2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness Routing
Views
Fuel Tank Pressure Sensor: Locations Harness Routing Views
Harness Routing Views
Chassis Harness Routing
1 - Chassis Frame 2 - Fuel Tank Pressure (FTP) Sensor 3 - Fuel Pump and Sender Assembly 4 Evaporative Emission (EVAP) Canister Vent Solenoid 5 - X402 (Chassis Harness to Right Rear
Lamp Assembly) 6 - J404 7 - X401 (Chassis Harness to Left Rear Lamp Assembly) 8 - X400
(Chassis Harness to License Lamp Harness) 9 - J403 10 - J402 11 - J400 12 - J401 13 - J310 14 X102 (Body Harness to Chassis Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness Routing
Views > Page 3174
Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views
Wheels/Vehicle Underbody Component Views
Rear of the Frame Components
1 - Evaporative Emission (EVAP) Canister Vent Solenoid 2 - Fuel Tank Pressure (FTP) Sensor 3 Fuel Pump and Sender Assembly 4 - Fuel Pump
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3175
Fuel Tank Pressure Sensor: Diagrams
Component Connector End Views
Fuel Tank Pressure (FTP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3176
Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor Replacement
Removal Procedure
1. Raise and support the vehicle, high enough to access the top of the fuel tank through the
wheelhouse liner. Refer to Lifting and Jacking the Vehicle
(See: Maintenance/Vehicle Lifting/Service and Repair).
2. If the vehicle is crew cab, lower the fuel tank. Refer to Fuel Tank Replacement (See: Fuel
Delivery and Air Induction/Fuel Tank/Service and
Repair).
3. Remove the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner
Replacement (See: Body and Frame/Fender/Rear
Fender/Rear Fender Liner/Service and Repair).
4. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor
(1). 5. Pull upward in order to remove the sensor from the fuel tank module.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3177
1. Lightly lubricate the sensor seal with clean engine oil. 2. Press the sensor fully into the fuel tank
module. 3. Connect the chassis wiring harness electrical connector to the pressure sensor (1). 4.
Install the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner
Replacement (See: Body and Frame/Fender/Rear
Fender/Rear Fender Liner/Service and Repair).
5. If the vehicle is a crew cab, install the fuel tank. Refer to Fuel Tank Replacement (See: Fuel
Delivery and Air Induction/Fuel Tank/Service and
Repair).
6. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams
Intake Air Temperature Sensor: Diagrams
Component Connector End Views
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 3181
Intake Air Temperature Sensor: Service and Repair
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Removal Procedure
Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not
dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do
not touch the sensing elements or allow anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct
only, to aid in installation.
1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor.
2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner
upper housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 3182
Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The
arrow must point toward the engine.
1. Install the MAF/IAT sensor (2) to the air cleaner upper housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the MAF/IAT sensor screws (1).
Tighten the screws to 1.5 Nm (13 lb in).
3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Engine - Right Side (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3186
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3187
Knock Sensor: Diagrams
Component Connector End Views
Knock Sensor (KS) 1 (LH8)
Knock Sensor (KS) 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3188
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1
Replacement
Knock Sensor: Service and Repair Knock Sensor 1 Replacement
Knock Sensor 1 Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS
retaining bolt. 4. Remove the KS (2) from the engine block.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1
Replacement > Page 3191
1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals
down.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1
Replacement > Page 3192
Knock Sensor: Service and Repair Knock Sensor 2 Replacement
Knock Sensor 2 Replacement
Removal Procedure
1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS)
through the wheelhouse. Refer to Lifting and Jacking
the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair).
2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body
and Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS
retaining bolt. 5. Remove the KS (1) from the engine block.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1
Replacement > Page 3193
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals
rearward.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left
wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and
Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Powertrain Component Views
Engine - Right Side (LH8)
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3197
Manifold Pressure/Vacuum Sensor: Diagrams
Component Connector End Views
Manifold Absolute Pressure (MAP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3198
Manifold Pressure/Vacuum Sensor: Service and Repair
Manifold Absolute Pressure Sensor Replacement
Removal Procedure
1. Remove the upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute
pressure (MAP) sensor.
3. Remove the MAP sensor retainer (1) from the intake manifold. 4. Remove the MAP sensor (2)
from the intake manifold.
Installation Procedure
Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3199
1. Install the MAP sensor (2) into the intake manifold. 2. Install the MAP sensor retainer (2) to the
intake manifold.
3. Connect the engine wiring harness electrical connector (3) to the MAP sensor. 4. Install the
upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Special Tools
J 41712 Oil Pressure Switch Socket
Removal Procedure
1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and
Repair).
2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor.
3. If not equipped with active fuel management perform the following step, using J 41712 or
equivalent, remove the oil pressure sensor (706) and
washer (707).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 3203
4. If equipped with active fuel management perform the following step, using J 41712 or equivalent,
remove the oil pressure sensor (706) and
washer (707).
Installation Procedure
1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids,
Lubricants, and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. If equipped with active fuel management perform the following step, using J 41712 or equivalent.
Install the oil pressure sensor (706) and washer
(707). Tighten the sensor to 35 Nm (26 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 3204
3. If not equipped with active fuel management, perform the following step, using J 41712 or
equivalent. Install the oil pressure sensor (706) and
washer (707).
4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the
sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement
(See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations
Oxygen Sensor: Locations
Powertrain Component Views
Rear of the Transmission Components
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3208
Oxygen Sensor: Diagrams
Component Connector End Views
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 (LH8)
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3209
Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (LH8)
Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3210
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and
Oxygen Sensor Caution
Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution
Excessive Force and Oxygen Sensor Caution
Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and
Oxygen Sensor Caution > Page 3213
Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution
Heated Oxygen and Oxygen Sensor Caution
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and
Oxygen Sensor Caution > Page 3214
Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution
Heated Oxygen Sensor Resistance Learn Reset Caution
Caution: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and
Oxygen Sensor Caution > Page 3215
Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution
Silicon Contamination of Heated Oxygen Sensors Caution
Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4)
from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the
rear HO2S electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 3218
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
4. Remove the HO2S (1).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 3219
2. Install the HO2S (1).
Tighten the sensor to 42 Nm (31 lb ft).
3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S
electrical connector (4) to the engine wiring harness electrical connector (1). 5. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 3220
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2)
from the engine wiring harness electrical connector (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 3221
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
3. Remove the HO2S (2).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 3222
2. Install the HO2S (2).
Tighten the sensor to 42 Nm (31 lb ft).
3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the
HO2S electrical connector (2) to the engine wiring harness electrical connector (3). 5. Lower the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 3223
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1
Heated Oxygen Sensor Replacement - Bank 2 Sensor 1
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2)
from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the
rear HO2S electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 3224
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
4. Remove the HO2S (1).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 3225
2. Install the HO2S (1).
Tighten the sensor to 42 Nm (31 lb ft).
3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S
electrical connector (2) to the engine wiring harness electrical connector (1). 5. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 3226
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2
Heated Oxygen Sensor Replacement - Bank 2 Sensor 2
Removal Procedure
Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4)
from the engine wiring harness electrical connector (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 3227
Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service
Precautions/Excessive Force and Oxygen Sensor Caution).
3. Remove the HO2S (2).
Installation Procedure
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New, or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or
equivalent.
Caution: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 3228
2. Install the HO2S (2).
Tighten the sensor to 42 Nm (31 lb ft).
3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the
HO2S electrical connector (4) to the engine wiring harness electrical connector (3). 5. Lower the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations
Transmission Position Switch/Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Left Side of the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
3232
1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
3233
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
3234
Transmission Position Switch/Sensor: Diagrams
Component Connector End Views
Park/Neutral Position (PNP) Switch (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
3235
Transmission Position Switch/Sensor: Service and Repair
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
2. Remove the following parts: (89), (92), (88), (85) and (84)
3. Remove the manual shaft seal (82) with a screwdriver.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
3236
1. Inspect the following items:
* Manual shaft (84) for damage or burrs
* Parking lock actuator assembly (85) for damage
* Manual shift detent lever with shaft position switch assembly (88) for damage or cracks
* Manual valve link (89) for damage
* Manual shift detent lever pin (92) discard - Do NOT reuse.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the following items:
* Manual shift detent lever with shaft position switch assembly (88)
* Parking lock actuator assembly (85)
* Manual shaft (84) (model dependent)
* NEW manual shift detent lever pin (92)
* Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft).
3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Vehicle Speed Sensor: Locations
Powertrain Component Views
Left Side of the Transmission Components (MA5)
Description
1 - Vehicle Speed Sensor (VSS)
Inside the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3240
36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift
Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid
Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC)
Pulse Width Modulation (PWM) Solenoid Valve
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3241
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3242
Vehicle Speed Sensor: Diagrams
Component Connector End Views
Vehicle Speed Sensor (VSS)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 Manual Transmission
Vehicle Speed Sensor: Service and Repair Aisin AR5 - Manual Transmission
Vehicle Speed Sensor Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the vehicle speed sensor (VSS) electrical connector (2).
3. Remove the VSS with O-ring seal.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 Manual Transmission > Page 3245
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
1. Install the VSS with O-ring seal.
Tighten the vehicle speed sensor (VSS) to 17 Nm (13 lb ft).
2. Connect the VSS electrical connector (2). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 Manual Transmission > Page 3246
Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission
Vehicle Speed Sensor Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the wiring harness electrical
connector from the vehicle speed sensor.
3. Remove the harness connector. 4. Remove the bolt (2). 5. Remove the vehicle speed sensor
(1). 6. Remove the O-ring seal (3).
Installation Procedure
1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin
film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the bolt (2) and tighten to 11 Nm (97 lb in). 5. Connect the wiring harness electrical
connector to the vehicle speed sensor. 6. Lower the vehicle. 7. Refill the fluid as required.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
Transmission Position Switch/Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Left Side of the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3250
1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3251
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3252
Transmission Position Switch/Sensor: Diagrams
Component Connector End Views
Park/Neutral Position (PNP) Switch (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3253
Transmission Position Switch/Sensor: Service and Repair
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
2. Remove the following parts: (89), (92), (88), (85) and (84)
3. Remove the manual shaft seal (82) with a screwdriver.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3254
1. Inspect the following items:
* Manual shaft (84) for damage or burrs
* Parking lock actuator assembly (85) for damage
* Manual shift detent lever with shaft position switch assembly (88) for damage or cracks
* Manual valve link (89) for damage
* Manual shift detent lever pin (92) discard - Do NOT reuse.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the following items:
* Manual shift detent lever with shaft position switch assembly (88)
* Parking lock actuator assembly (85)
* Manual shaft (84) (model dependent)
* NEW manual shift detent lever pin (92)
* Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft).
3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing
Solenoid > Component Information > Diagrams
Variable Valve Timing Solenoid: Diagrams
Component Connector End Views
Camshaft Position (CMP) Actuator Solenoid Valve
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations
Vehicle Speed Sensor: Locations
Powertrain Component Views
Left Side of the Transmission Components (MA5)
Description
1 - Vehicle Speed Sensor (VSS)
Inside the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations > Page 3261
36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift
Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid
Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC)
Pulse Width Modulation (PWM) Solenoid Valve
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations > Page 3262
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations > Page 3263
Vehicle Speed Sensor: Diagrams
Component Connector End Views
Vehicle Speed Sensor (VSS)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Service and Repair > Aisin AR5 - Manual Transmission
Vehicle Speed Sensor: Service and Repair Aisin AR5 - Manual Transmission
Vehicle Speed Sensor Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the vehicle speed sensor (VSS) electrical connector (2).
3. Remove the VSS with O-ring seal.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Service and Repair > Aisin AR5 - Manual Transmission > Page 3266
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
1. Install the VSS with O-ring seal.
Tighten the vehicle speed sensor (VSS) to 17 Nm (13 lb ft).
2. Connect the VSS electrical connector (2). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Service and Repair > Aisin AR5 - Manual Transmission > Page 3267
Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission
Vehicle Speed Sensor Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the wiring harness electrical
connector from the vehicle speed sensor.
3. Remove the harness connector. 4. Remove the bolt (2). 5. Remove the vehicle speed sensor
(1). 6. Remove the O-ring seal (3).
Installation Procedure
1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin
film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the bolt (2) and tighten to 11 Nm (97 lb in). 5. Connect the wiring harness electrical
connector to the vehicle speed sensor. 6. Lower the vehicle. 7. Refill the fluid as required.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump >
Component Information > Diagrams
Air Injection Pump: Diagrams
Component Connector End Views
Secondary Air Injection (AIR) Pump (K18)
Secondary Air Injection (AIR) Pump Solenoid (K18)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump >
Component Information > Diagrams > Page 3273
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump
Relay > Component Information > Diagrams
Air Injection Pump Relay: Diagrams
Component Connector End Views
Secondary Air Injection (AIR) Pump Relay (K18)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst
Shield > Component Information > Service and Repair
Catalyst Shield: Service and Repair
Catalytic Converter Heat Shield Replacement
Removal Procedure Warning: Refer to Exhaust Service Warning (See: Engine, Cooling and
Exhaust/Exhaust System/Service Precautions).
Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician
Safety Information/Protective Goggles and Glove Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Remove the 5 nuts securing the heat shield to the floor panel. 3. Remove the catalytic converter
heat shield from the floor panel.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst
Shield > Component Information > Service and Repair > Page 3281
1. Position the catalytic converter heat shield to the floor panel studs.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the 5 nuts securing the heat shield to the floor panel. Tighten the heat shield nuts to 9 Nm
(80 lb in). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams
Canister Purge Solenoid: Diagrams
Component Connector End Views
Evaporative Emission (EVAP) Canister Purge Solenoid Valve
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Page 3286
Canister Purge Solenoid: Service and Repair
Evaporative Emission Canister Purge Solenoid Valve Replacement
Removal Procedure
1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement
(See: Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
2. Disconnect the chassis evaporative emission (EVAP) line quick connect fitting (1) from the EVAP
canister purge solenoid valve. Refer to Plastic
Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line
Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
3. Disconnect the engine EVAP line (1) quick connect fitting from the EVAP canister purge solenoid
valve. Refer to Plastic Collar Quick Connect
Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic
Collar Quick Connect Fitting Service).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Page 3287
4. Disconnect the engine wiring harness electrical connector (3) from the EVAP canister purge
solenoid valve.
5. Using a small flat bladed tool, disengage the retaining tab, and remove the EVAP canister purge
solenoid valve (1) from the fuel rail bracket.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Page 3288
1. Using a small flat bladed tool, reposition the retaining tab if necessary. 2. Install the EVAP
canister purge solenoid valve (1) to the fuel rail bracket.
3. Connect the engine wiring harness electrical connector (3) to the EVAP canister purge solenoid
valve.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Page 3289
4. Connect the engine EVAP line (1) quick connect fitting to the EVAP canister purge solenoid
valve. Refer to Plastic Collar Quick Connect Fitting
Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar
Quick Connect Fitting Service).
5. Connect the chassis EVAP line quick connect fitting (1) to the EVAP canister purge solenoid
valve. Refer to Plastic Collar Quick Connect Fitting
Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar
Quick Connect Fitting Service).
6. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Wheels/Vehicle
Underbody Component Views
Canister Vent Valve: Locations Wheels/Vehicle Underbody Component Views
Wheels/Vehicle Underbody Component Views
Rear of the Frame Components
1 - Evaporative Emission (EVAP) Canister Vent Solenoid 2 - Fuel Tank Pressure (FTP) Sensor 3 Fuel Pump and Sender Assembly 4 - Fuel Pump
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Wheels/Vehicle
Underbody Component Views > Page 3295
Canister Vent Valve: Locations Harness Routing Views
Harness Routing Views
Chassis Harness Routing
1 - Chassis Frame 2 - Fuel Tank Pressure (FTP) Sensor 3 - Fuel Pump and Sender Assembly 4 Evaporative Emission (EVAP) Canister Vent Solenoid 5 - X402 (Chassis Harness to Right Rear
Lamp Assembly) 6 - J404 7 - X401 (Chassis Harness to Left Rear Lamp Assembly) 8 - X400
(Chassis Harness to License Lamp Harness) 9 - J403 10 - J402 11 - J400 12 - J401 13 - J310 14 X102 (Body Harness to Chassis Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3296
Canister Vent Valve: Diagrams
Component Connector End Views
Evaporative Emission (EVAP) Canister Vent Solenoid
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3297
Canister Vent Valve: Service and Repair
Evaporative Emission Canister Vent Solenoid Valve Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the evaporative emission (EVAP)
canister vent solenoid valve electrical connector (1).
3. Disconnect the fuel fill pipe vapor line quick connect (1) from the EVAP canister. Refer to Plastic
Collar Quick Connect Fitting Service (See:
Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect
Fitting Service).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3298
4. Disconnect the EVAP canister vent solenoid valve quick connect from the EVAP canister. Refer
to Plastic Collar Quick Connect Fitting Service (
See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick
Connect Fitting Service).
5. Disengage the bracket retaining tab and remove the EVAP canister vent solenoid valve (1).
Installation Procedure
1. Engage the bracket retaining tab and install the EVAP canister vent solenoid valve (1). 2.
Connect the EVAP canister vent solenoid valve quick connect to the EVAP canister. Refer to
Plastic Collar Quick Connect Fitting Service (See:
Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect
Fitting Service).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3299
3. Connect the fuel fill pipe vapor line quick connect (1) to the EVAP canister. Refer to Plastic
Collar Quick Connect Fitting Service (See: Fuel
Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect
Fitting Service).
4. Connect the EVAP canister vent solenoid valve electrical connector (1). 5. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Canister/Fuel Tank
Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Canister/Fuel Tank
Evaporative Emission Hoses/Pipes Replacement - Canister/Fuel Tank
Removal Procedure Warning: Refer to Fuel and Evaporative Emission Pipe Warning (See: Service
Precautions/Technician Safety Information).
Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air
Induction/Fuel/Service Precautions).
Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (See:
Service Precautions/Vehicle Damage Warnings/Fuel and Evaporative Emission Hose/Pipe
Connection Cleaning Caution).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel
Line Coupler/Service and Repair/Plastic Collar
Quick Connect Fitting Service) in order to disconnect the evaporative emission (EVAP) hoses (1, 3)
from the following:
* The EVAP canister (5)
* The vent valve
3. Disengage the EVAP hose (3) from the retaining clip on the fuel tank.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Canister/Fuel Tank > Page 3304
1. Secure the EVAP hose (3) to the retaining clip on the fuel tank. 2. Refer to Plastic Collar Quick
Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and
Repair/Plastic Collar
Quick Connect Fitting Service) in order to connect the EVAP hoses (1, 3) to the following:
* The EVAP canister (5)
* The vent valve
3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Canister/Fuel Tank > Page 3305
Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Chassis
Evaporative Emission Hose/Pipe Replacement - Chassis
Removal Procedure Warning: Refer to Fuel and Evaporative Emission Pipe Warning (See: Service
Precautions/Technician Safety Information).
Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air
Induction/Fuel/Service Precautions).
Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (See:
Service Precautions/Vehicle Damage Warnings/Fuel and Evaporative Emission Hose/Pipe
Connection Cleaning Caution).
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel
Delivery and Air Induction/Fuel Filter/Fuel Pressure
Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without
CH-48027) (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and
Repair/Fuel Pressure Relief (Without CH-48027)).
2. Disconnect the chassis fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal
Collar Quick Connect Fitting Service (See: Fuel
Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting
Service).
3. Disconnect the chassis evaporative emission (EVAP) line quick connect fitting (1) from the EVAP
purge solenoid. Refer to Plastic Collar Quick
Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and
Repair/Plastic Collar Quick Connect Fitting Service).
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel pipe bracket nut (3) from the
transmission stud. 6. Remove the fuel pipe bracket from the stud.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Canister/Fuel Tank > Page 3306
7. Disconnect the fuel tank fuel feed line quick connect fitting (4) from the chassis fuel feed line.
Refer to Plastic Collar Quick Connect Fitting
Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar
Quick Connect Fitting Service).
8. Disconnect the EVAP line quick connect fitting (1) from the chassis EVAP line. Refer to Plastic
Collar Quick Connect Fitting Service (See: Fuel
Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect
Fitting Service).
9. Remove the chassis fuel feed and EVAP line bracket bolt (2).
10. Lift the chassis fuel feed and EVAP line assembly (3) up in order the remove the bracket tab
from the crossmember.
11. Remove the fuel feed and EVAP line clip (4) from the fuel line bracket. 12. Remove the fuel
pipe bracket bolt (6). 13. Remove the fuel feed and EVAP pipe assembly (3) from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Canister/Fuel Tank > Page 3307
1. Install the fuel feed and EVAP pipe assembly (3) to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Position the fuel pipe bracket (5) and install the bracket bolt (6).
Tighten the bolt to 4.5 Nm (40 lb in).
3. Install the fuel feed and EVAP line clip (4) to the fuel line bracket.
4. Position the chassis fuel feed and EVAP line assembly (3) bracket tab to the crossmember. 5.
Install the chassis fuel feed and EVAP line bracket bolt (2).
Tighten the bolt to 10 Nm (89 lb in).
6. Connect the EVAP line quick connect fitting (1) to the chassis EVAP line. Refer to Plastic Collar
Quick Connect Fitting Service (See: Fuel
Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect
Fitting Service).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Canister/Fuel Tank > Page 3308
7. Connect the fuel tank fuel feed line quick connect fitting (4) to the chassis fuel feed line. Refer to
Plastic Collar Quick Connect Fitting Service (
See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick
Connect Fitting Service).
8. Install the fuel pipe bracket onto the stud. 9. Install the fuel pipe bracket nut (3) to the
transmission stud.
Tighten the nut to 9 Nm (80 lb in).
10. Lower the vehicle. 11. Connect the chassis fuel feed line quick connect fitting (2) to the fuel rail.
Refer to Metal Collar Quick Connect Fitting Service (See: Fuel
Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting
Service).
12. Connect the chassis EVAP line quick connect fitting (1) to the EVAP purge solenoid. Refer to
Plastic Collar Quick Connect Fitting Service (See:
Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect
Fitting Service).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Canister/Fuel Tank > Page 3309
Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Engine
Evaporative Emission Hoses/Pipes Replacement - Engine
Removal Procedure
Important: Clean the tube connections and surrounding areas before disconnecting in order to
avoid possible evaporative emission (EVAP) system contamination.
1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement
(See: Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
2. Disconnect the engine EVAP line (1) quick connect fitting from the intake manifold. Refer to
Plastic Collar Quick Connect Fitting Service (See:
Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect
Fitting Service).
3. Disconnect the engine EVAP line (1) quick connect fitting from the EVAP canister purge solenoid
valve. Refer to Plastic Collar Quick Connect
Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic
Collar Quick Connect Fitting Service).
4. Cap the intake manifold port and the EVAP canister purge solenoid valve in order to prevent
possible EVAP system contamination.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Canister/Fuel Tank > Page 3310
1. Remove the caps from the intake manifold port and the EVAP canister purge solenoid valve. 2.
Connect the engine EVAP line (1) quick connect fitting to the EVAP canister purge solenoid valve.
Refer to Plastic Collar Quick Connect Fitting
Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar
Quick Connect Fitting Service).
3. Connect the engine EVAP line (1) quick connect fitting to the intake manifold. Refer to Plastic
Collar Quick Connect Fitting Service (See: Fuel
Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect
Fitting Service).
4. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
PCV Valve Hose > Component Information > Service and Repair
PCV Valve Hose: Service and Repair
Positive Crankcase Ventilation Hose/Pipe/Tube Replacement
Removal Procedure
1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair).
2. Remove the positive crankcase ventilation (PCV) hose from the intake manifold fitting and left
valve rocker arm cover, if required.
3. Remove the PCV tube (1) from the air cleaner outlet duct, if required.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
PCV Valve Hose > Component Information > Service and Repair > Page 3315
4. Remove the PCV tube (1) from the right valve rocker arm cover fitting (2), if required. 5. Remove
the appropriate PCV hose/tube from the vehicle.
Installation Procedure
1. Install the appropriate PCV hose/tube to the vehicle. 2. Install the PCV tube (1) to the right valve
rocker arm cover fitting (2), if required.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
PCV Valve Hose > Component Information > Service and Repair > Page 3316
Important: Route the PCV tube between the engine harness and generator battery jumper cable.
3. Install the PCV tube (1) to the air cleaner outlet duct, if required.
4. Install the PCV hose to the intake manifold fitting and left valve rocker arm cover, if required. 5.
Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement
(See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission
Control Systems > Air Injection Pump Relay > Component Information > Diagrams
Air Injection Pump Relay: Diagrams
Component Connector End Views
Secondary Air Injection (AIR) Pump Relay (K18)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > Specifications
Fuel Pressure: Specifications
Fuel pressure (Ignition ON, engine OFF).............................................................................................
..............................................345-414 kPa (50-60 psi) fuel pressure should not decrease more than
34 kPa (5 psi) in 1 minute
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > Specifications > Page 3325
Fuel Pressure: Service Precautions
Relieving Fuel Pressure Warning
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > Specifications > Page 3326
Fuel Pressure: Testing and Inspection
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category.
Circuit/System Description
The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when
the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for
2 seconds unless the engine is in Crank or Run. While this voltage is being received, the FPCM
closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump
module in order to maintain the desired fuel rail pressure.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel
pump module, eliminating the need for a return pipe from the engine. A returnless fuel system
reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the
fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.
The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump
module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and
the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of the
flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump
located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel
pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the
correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow
check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed
pipe and the fuel rail in order to prevent long cranking times.
Electrical Information Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning)for scan
tool information Special Tools
* CH 48027 - Fuel Pressure Gage
* J 37287 - Fuel Line Shut-Off Adapters
Circuit/System Verification
Note: *
Inspect the fuel system for damage or external leaks before proceeding.
* Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
1. Ignition OFF, all accessories OFF, install the CH 48027 - Gage. Refer to Fuel Pressure Gage
Installation and Removal (See: Fuel Filter/Fuel
Pressure Release/Service and Repair/Fuel Pressure Gage Installation and Removal).
2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is
between 345-414 kPa (50-60 psi) and remains steady
for 5 minutes.
Circuit/System Testing
Note: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure
gage while the fuel pump is operating. Verify the
fuel pressure is between 345-414 kPa (50-60 psi).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > Specifications > Page 3327
‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel
pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the
items listed below. If all items test
normal, replace the fuel pump.
* Restricted fuel feed pipe
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
Note: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump
stops operating, the fuel pressure should stabilize and remain constant.
2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
‹› If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See:
Fuel Filter/Fuel Pressure Release/Service and
Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)).
2. Install the J 37287 - Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the
valve on the J 37287 - Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a
scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 Shut-Off Adapters. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1
minute.
‹› If the fuel pressure drops, locate and replace the leaking fuel injector.
7. If the fuel system test normal, replace the fuel pump.
3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
‹› If the fuel pressure decreases more than the specified value, replace the fuel pump.
4. Operate the vehicle within the Conditions of the customer's concern while monitoring the fuel
pressure with the CH 48027 - Gage. The fuel
pressure should not drop off during acceleration, cruise or hard cornering.
‹› If the fuel pressure drops off, test, inspect and repair the items listed below. If all items test
normal, replace the fuel sender.
* Restricted fuel feed pipe
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and
Control Systems/Testing and Inspection/Symptom
Related Diagnostic Procedures/Symptoms - Engine Controls).
Repair Instructions
Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures) after completing the diagnostic procedure.
* Fuel Hose/Pipes Replacement - Chassis (See: Fuel Return Line/Service and Repair)
* Fuel Injector Replacement (See: Fuel Injector/Service and Repair/Removal and Replacement)
* Fuel Tank Fuel Pump Module Replacement (See: Fuel Pump/Service and Repair)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning
(See: Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID).
2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine
cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail
service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten
the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3332
Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service
Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel
Pressure Relief (With CH 48027))Fuel Pressure
Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)).
2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or
diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's
directions.
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3333
1. Relieve the fuel system pressure, if required. Perform the following steps:
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from
the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the
fuel rail service port cap. 6. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3334
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH-48027)
Special Tools
CH-48027 - Digital Pressure Gage
Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID).
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3335
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT
necessary to proceed with the following steps.
12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4)
from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and
place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the
engine cover, if required. 17. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views
Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Behind the Left Side of the I/P Components
1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal
Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition
Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3340
Accelerator Pedal Position Sensor: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3341
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3342
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3343
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3344
25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to
Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to
Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33
- Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 3345
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 3346
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP
sensor nuts. 3. Remove the APP sensor from the vehicle.
Installation Procedure
1. Position the APP sensor over the studs.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 3347
2. Install the APP sensor nuts.
Tighten the APP sensor mounting nuts to 9 Nm (80 lb in).
3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure
full range of motion.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air
Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Resonator Outlet Duct Replacement
Removal Procedure
1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement
(See: Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct.
3. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air
Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3352
4. Loosen the air cleaner outlet duct clamp (1) at the throttle body. 5. Grasp the air cleaner outlet
duct near the ball stud and firmly pull up in order to disengage the duct from the ball stud. 6.
Remove the air cleaner outlet duct (2) from the throttle body and the air cleaner housing.
Installation Procedure
1. Install the air cleaner outlet duct (2) to the throttle body and the air cleaner housing. 2. Ensure
that the air cleaner outlet duct tab rests over the ball stud, press down on the duct tab in order to
engage the duct to the ball stud.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the air cleaner outlet duct clamp (1) at the throttle body.
Tighten the clamp to 3.5 Nm (31 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air
Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3353
4. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing.
Tighten the clamp to 3.5 Nm (31 lb in).
5. Install the PCV line (1) to the air cleaner outlet duct. 6. Install the intake manifold cover. Refer to
Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Air Cleaner Fresh Air Duct/Hose/Service and
Repair).
2. Release the air cleaner upper housing retainer clips (1).
3. Open the air cleaner upper housing (1). 4. Remove the air filter element (2) from the lower air
cleaner housing. 5. Inspect the air cleaner assembly for debris or damage and repair as necessary.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 3357
1. Install the air filter element (2) to the lower air cleaner housing. 2. Close the air cleaner upper
housing (1).
3. Latch the air cleaner upper housing retainer clips (1). 4. Install the air cleaner outlet duct. Refer
to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service
and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams
Air Flow Meter/Sensor: Diagrams
Component Connector End Views
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 3361
Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Removal Procedure
Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not
dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do
not touch the sensing elements or allow anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct
only, to aid in installation.
1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor.
2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner
upper housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 3362
Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The
arrow must point toward the engine.
1. Install the MAF/IAT sensor (2) to the air cleaner upper housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the MAF/IAT sensor screws (1).
Tighten the screws to 1.5 Nm (13 lb in).
3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y.
Fuel: Technical Service Bulletins Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y.
INFORMATION
Bulletin No.: 10-06-04-015
Date: December 08, 2010
Subject: General Motors' Position Regarding Use of E15 in Model Year 2007 and Newer Vehicles
Models:
2007-2011 GM Passenger Cars and Trucks
General Motors' position regarding the Environmental Protection Agency announcement allowing
the use of E 15 in 2007 and newer vehicles:
- General Motors' remains focused on securing a safe and positive driving experience for our
customers. GM believes that the waiver decision by the EPA regarding E 15 could lead to
confusion for consumers as to what fuel their vehicle should use. In response, we will continue to
encourage our customers to refer to their vehicle Owner Manual for proper fuel designation. The
vehicle Owner Manual specifies that fuels containing more than 10 percent ethanol should not be
used in GM vehicles that do not have a flex fuel designation.
- GM has the largest fleet of flex fuel vehicles on the road today (over 4 million in the U.S.) and
these vehicles can safely use ethanol blends of up to 85 percent ethanol. So blends of E 15 (15
percent ethanol), as in the partial waiver announced, are appropriate for these vehicles. However,
ethanol blends greater than E 10 should not be used in GM vehicles that do not have a flex fuel
designation as they are not designed and certified to run on gasoline consisting of more than 10
percent ethanol-blend volume to avoid any unintended consequences, as per: their Owner Manual.
- We believe biofuels, especially E 85 ethanol, are an effective near-term solution to reduce
petroleum dependence and the carbon footprint of driving. As the global leader in producing
vehicles designed to handle ethanol blends from E 0 to E 85, GM offers 19 flexible-fuel vehicles for
the 2011 model year.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 3367
Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada)
INFORMATION
Bulletin No.: 05-06-04-022G
Date: October 27, 2010
Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel
Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY
Models:
2011 and Prior GM Passenger Cars and Trucks (Canada Only)
Supercede: This bulletin is being revised to update the model years and include an additional
gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F
(Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate
Bulletin Number 04-06-04-047I.
A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel
marketers. This gasoline meets detergency standards developed by six automotive companies. All
vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest
Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those
vehicles that have experienced deposit related concerns may especially benefit from use of TOP
TIER Detergent Gasoline.
Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline
Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB
Top Tier Fuel Availability
Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first
national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada
began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began
offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent
Gasoline in May of 2010.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 3368
Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards
The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane
grades :
Chevron Canada (markets in British Columbia and western Alberta)
- Shell Canada (nationally)
- Petro-Canada (nationally)
- Sunoco-Canada (Ontario)
- Esso-Canada (nationally)
What is TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no
metallic additives. It meets new, voluntary deposit control standards developed by six automotive
companies that exceed the detergent recommendations of Canadian standards and does not
contain metallic additives, which can damage vehicle emission control components.
Where Can TOP TIER Detergent Gasoline Be Purchased?
The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have
already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not
all fuel marketers will offer this product. Once fuel marketers make public announcements, they will
appear on a list of brands that meet the TOP TIER standards.
Who developed TOP TIER Detergent Gasoline standards?
TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW,
General Motors, Honda, Toyota, Volkswagen and Audi.
Why was TOP TIER Detergent Gasoline developed?
TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in
gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a
detergent additive. However, the requirement is minimal and in many cases, is not sufficient to
keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency
requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any
detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of
detergent is needed than what is required or recommended, and no metallic additives are allowed.
Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product.
Why did the six automotive companies join together to develop TOP TIER?
All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining
together emphasized that low detergency and the intentional addition of metallic additives is an
issue of concern to several automotive companies.
What are the benefits of TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest
Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal
fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP
TIER Detergent Gasoline will help reduce deposit related concerns.
Who should use TOP TIER Detergent Gasoline?
All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the
"Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have
experienced deposit related concerns may especially benefit from use of TOP TIER Detergent
Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website,
http://www.toptiergas.com/.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 3369
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 3370
Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information
INFORMATION
Bulletin No.: 04-06-04-047I
Date: August 17, 2009
Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance,
Stall Concerns) - U.S. Only
Models:
2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010
HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only)
Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier
Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F.
A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel
marketers. This gasoline meets detergency standards developed by six automotive companies. All
vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest
Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related
concerns may especially benefit from the use of TOP TIER Detergent Gasoline.
Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline
Intake valve: - 10,000 miles with Legal Minimum additive
Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards
As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent
Gasoline Standards:
- Chevron
- Chevron-Canada
- QuikTrip
- Conoco
Phillips 66
- 76
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 3371
- Shell
- Shell-Canada
- Entec Stations located in the greater Montgomery, Alabama area.
- MFA Oil Company located throughout Missouri.
- Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa.
The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky.
Aloha Petroleum
- Tri-Par Oil Company
- Turkey Hill Minit Markets
- Texaco
- Petro-Canada
- Sunoco-Canada
- Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin
What is TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new,
voluntary deposit control standards developed by six automotive companies that exceed the
detergent requirements imposed by the EPA.
Where Can TOP TIER Detergent Gasoline Be Purchased?
The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program
and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel
marketers will offer this product. Once fuel marketers make public announcements, they will appear
on a list of brands that meet the TOP TIER standards.
Where Can I find the Latest Information on TOP TIER Fuel and Retailers?
On the web, please visit www.toptiergas.com for additional information and updated retailer lists.
Who developed TOP TIER Detergent Gasoline standards?
TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi,
BMW, General Motors, Honda, Toyota and Volkswagen.
Why was TOP TIER Detergent Gasoline developed?
TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in
gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However,
the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to
meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is
required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to
differentiate their product.
Why did the six automotive companies join together to develop TOP TIER?
All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining
together emphasized that low detergency is an issue of concern to several automotive companies.
What are the benefits of TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest
Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and
performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce
deposit related concerns.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Page 3372
Fuel: Service Precautions
Gasoline/Gasoline Vapors Warning
Warning
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is
present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of
fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Testing and Inspection > Alcohol/Contaminants-in-Fuel Diagnosis (without Special Tool)
Fuel: Testing and Inspection Alcohol/Contaminants-in-Fuel Diagnosis (without Special Tool)
Alcohol/Contaminants-in-Fuel Diagnosis (without Special Tool)
Description
Water contamination in the fuel system may cause driveability conditions such as hesitation,
stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector
at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel
system is contaminated with water, inspect the fuel system components for rust, or deterioration.
Alcohol concentrations of 10 percent or greater in fuel can be detrimental to fuel system
components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber
components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to
fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations
of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol.
Fuel with more than 10 percent ethanol may cause driveability conditions such as hesitation, lack
of power, stalling, or no start.
Alcohol in Fuel Testing Procedure
The fuel sample should be drawn from the bottom of the tank so that any water present in the tank
will be detected. The sample should be bright and clear. If alcohol contamination is suspected then
use the following procedure to test the fuel quality.
1. Using a 100 ml (3.4 oz) specified cylinder with 1 ml (0.03 oz) graduation marks, fill the cylinder
with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid
volume to 100 ml (3.4 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds.
4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake
the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for
approximately 5 minutes in order to allow adequate liquid separation.
If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol
and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is
increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount
of alcohol may be somewhat more because this procedure does not extract all of the alcohol from
the fuel.
Particulate Contaminants in Fuel Testing Procedure
The fuel sample should be drawn from the bottom of the tank so that any water present in the tank
will be detected. The sample should be bright and clear. If the sample appears cloudy, or
contaminated with water, as indicated by a water layer at the bottom of the sample, use the
following procedure to diagnose the fuel.
1. Using an approved fuel container, draw approximately 0.5 liter (0.13 gal) of fuel. 2. Place the
cylinder on a level surface for approximately 5 minutes in order to allow settling of the particulate
contamination.
Particulate contamination will show up in various shapes and colors. Sand will typically be identified
by a white or light brown crystals. Rubber will appear as black and irregular particles. If particles
are found clean the entire fuel system thoroughly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Testing and Inspection > Alcohol/Contaminants-in-Fuel Diagnosis (without Special Tool) > Page 3375
Fuel: Testing and Inspection Alcohol/Contaminants-in-Fuel Diagnosis (with Special Tool)
Alcohol/Contaminants-in-Fuel Diagnosis (with Special Tool)
Description
Water contamination in the fuel system may cause driveability conditions such as hesitation,
stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector
at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel
system is contaminated with water, inspect the fuel system components for rust or deterioration.
Ethanol concentrations of greater than 10 percent can cause driveability conditions and fuel system
deterioration. Fuel with more than 10 percent ethanol could result in driveability conditions such as
hesitation, lack of power, stalling , or no start. Excessive concentrations of ethanol used in vehicles
not designed for it may cause fuel system corrosion, deterioration of rubber components, and fuel
filter restriction.
Test Procedure
1. Test the fuel composition using J 44175 Fuel Composition Tester and J44175-3 Instruction
Manual. 2. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in
the fuel sample. Refer to the examples in the Fuel
Composition Test Examples table.
3. If the fuel sample contains more than 15 percent ethanol, add fresh, regular gasoline to the
vehicle's fuel tank. 4. Test the fuel composition. 5. If testing shows the ethanol percentage is still
more than 15 percent, replace the fuel in the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027)
Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning
(See: Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID).
2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine
cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail
service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten
the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3381
Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service
Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel
Pressure Relief (With CH 48027))Fuel Pressure
Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)).
2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or
diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's
directions.
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3382
1. Relieve the fuel system pressure, if required. Perform the following steps:
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from
the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the
fuel rail service port cap. 6. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3383
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH-48027)
Special Tools
CH-48027 - Digital Pressure Gage
Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions).
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID).
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Warning
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel
pressure gage. Place the towel in an approved container when the connection of the fuel pressure
gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3384
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT
necessary to proceed with the following steps.
12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4)
from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and
place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the
engine cover, if required. 17. Tighten the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's
Fuel Injector: Customer Interest Fuel System - Driveability Issues/MIL/Multiple DTC's
TECHNICAL
Bulletin No.: 03-06-04-030G
Date: April 22, 2009
Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171,
P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT
CH-47976)
Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2
2006-2009 HUMMER H3 2005-2009 Saab 9-7X
Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors
Attention:
GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines
other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should
have those injectors replaced.
Supercede: This bulletin is being revised to update the model year to 2009 and to provide
applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section
06 - Engine/Propulsion System).
Condition
Some customers may comment on any of the following various driveability symptoms:
- Extended Crank Time
- Hard to Start
- MIL/SES Illuminated with DTCs
- Hesitation
- Lack of Power
- Surge or Chuggle
- Rough Idle
- Light or Intermittent Misfire
Cause
Due to various factors, the fuel injectors may become restricted. Extensive testing has
demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific
fuel, fuel constituent, or engine condition has been identified as causing the restriction. The
restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to
illuminate or the engine to develop various driveability symptoms.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 3393
Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure.
Under NO circumstances should this procedure be modified, changed or shortened. As a long term
solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent
Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to
the following Corporate Bulletin Numbers:
- 04-06-04-047G (U.S. Only)
- 05-06-04-022D (Canada ONLY)
Notice
GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent
approved for use with General Motors fuel system components. Other injector cleaners may cause
damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory
testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with
General Motors fuel system components, as long as the cleaning procedure is followed correctly.
Injector Cleaning Procedure
The following tools, or their equivalent, are required:
- CH-47976 Active Fuel Injector Tester (AFIT)
- J 35800-A Fuel Injector Cleaner
- J 37287 Fuel Line Shut-off Adapter
- J 42964 Fuel Line Shut-off Adapter
- J 42873 Fuel Line Shut-off Adapter
- * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N
88861804)
- * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012)
Active Fuel Injector Tester (AFIT- CH-47976)
Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact
to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel
Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI.
Important
As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be
tested with the AFIT. Depending on the model, it may be possible to enter the previous model year
and proceed with testing using the DLC connection. If this is not possible on the model that you are
working on, it will be necessary to use the direct connection method outlined in the AFIT User
Guide (See Pages 17-31).
General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel
injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector
Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide.
The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more
precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the
AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel
injector concern).
The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and
fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current
counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing
the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions.
Training (U.S.)
To access the training video on AFIT, take the following path at the GM Training Website:
1. After logging into the training website, choose the link on the left side of the page titled "web
video library."
2. Then choose "technical."
3. Next, within the search box, type in September course number "10206.09D.
4. This will bring up a link with this course. Scroll through to choose "feature topic."
5. At this point, the seminar can be chosen to view or the video related to the AFIT.
Additional training is available from the training website. Please see TECHassist 16044.18T2
Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more
information on GM Upper Engine and Fuel Injector Cleaner.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 3394
Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE).
Training (Canada)
To access the training video on AFIT, take the following path at the GMPro LMS Training Website:
1. After logging into the website, choose the link on the left side of the page titled "Catalog."
2. Then choose "Catalog Search."
3. Next, within the search box, Select Course Number - Contains - "T" then select search.
4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector
Tester" and select "View."
5. At this point, a new window will open and the program can be Launched.
Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE).
Techlink
Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel
Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following
path:
1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada).
2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service
Library of GM GlobalConnect).
3. Click on the GM Techlink Hyperlink.
4. Click on the Archives Hyperlink at GM Techlink.
- Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the
June 2006 Techlink Article.
- Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link
in the November 2006 Techlink Article.
Injector Cleaning Procedure
Notice
GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent
recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN
METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances
should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank.
Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that
exceeding the recommended cleaning solution concentration does not improve the effectiveness of
this procedure.
Important
Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned.
These vehicles should have any out of specification injectors replaced.
1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper
Engine and Fuel Injector Cleaner container into the J
35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are
using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14
oz) of regular unleaded gasoline.
2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and
Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any
other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector
Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be
repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline.
3. Be sure to follow all additional instructions provided with the tool.
4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump
relay and disconnecting the oil pressure switch
connector, if equipped.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 3395
5. Turn the ignition to the OFF position.
6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel
feed and return lines coming off the fuel rail with J
37287, J 42873 or J 42964 as appropriate for the fuel system.
7. Connect the J 35800-A to the vehicle fuel rail.
8. Pressurize the J 35800-A to 510 kPa (75 psi).
9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20
minutes.
10. Turn the ignition to the OFF position.
11. Disconnect the J 35800-A from the fuel rail.
12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped.
13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines.
14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is
flushed from the fuel rail and fuel lines.
15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N
88861012]) into the tank and advise the customer to
fill the tank.
16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend
that they add a bottle of GM Fuel System Treatment
Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should
keep the customer from having to repeat the injector cleaning procedure.
17. Road test the vehicle to verify that the customer concern has been corrected.
Parts Information
* Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder
engines.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Warranty Information (Saab U.S. Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 3396
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's
Fuel Injector: All Technical Service Bulletins Fuel System - Driveability Issues/MIL/Multiple DTC's
TECHNICAL
Bulletin No.: 03-06-04-030G
Date: April 22, 2009
Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171,
P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT
CH-47976)
Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2
2006-2009 HUMMER H3 2005-2009 Saab 9-7X
Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors
Attention:
GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines
other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should
have those injectors replaced.
Supercede: This bulletin is being revised to update the model year to 2009 and to provide
applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section
06 - Engine/Propulsion System).
Condition
Some customers may comment on any of the following various driveability symptoms:
- Extended Crank Time
- Hard to Start
- MIL/SES Illuminated with DTCs
- Hesitation
- Lack of Power
- Surge or Chuggle
- Rough Idle
- Light or Intermittent Misfire
Cause
Due to various factors, the fuel injectors may become restricted. Extensive testing has
demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific
fuel, fuel constituent, or engine condition has been identified as causing the restriction. The
restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to
illuminate or the engine to develop various driveability symptoms.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 3402
Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure.
Under NO circumstances should this procedure be modified, changed or shortened. As a long term
solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent
Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to
the following Corporate Bulletin Numbers:
- 04-06-04-047G (U.S. Only)
- 05-06-04-022D (Canada ONLY)
Notice
GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent
approved for use with General Motors fuel system components. Other injector cleaners may cause
damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory
testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with
General Motors fuel system components, as long as the cleaning procedure is followed correctly.
Injector Cleaning Procedure
The following tools, or their equivalent, are required:
- CH-47976 Active Fuel Injector Tester (AFIT)
- J 35800-A Fuel Injector Cleaner
- J 37287 Fuel Line Shut-off Adapter
- J 42964 Fuel Line Shut-off Adapter
- J 42873 Fuel Line Shut-off Adapter
- * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N
88861804)
- * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012)
Active Fuel Injector Tester (AFIT- CH-47976)
Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact
to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel
Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI.
Important
As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be
tested with the AFIT. Depending on the model, it may be possible to enter the previous model year
and proceed with testing using the DLC connection. If this is not possible on the model that you are
working on, it will be necessary to use the direct connection method outlined in the AFIT User
Guide (See Pages 17-31).
General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel
injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector
Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide.
The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more
precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the
AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel
injector concern).
The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and
fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current
counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing
the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions.
Training (U.S.)
To access the training video on AFIT, take the following path at the GM Training Website:
1. After logging into the training website, choose the link on the left side of the page titled "web
video library."
2. Then choose "technical."
3. Next, within the search box, type in September course number "10206.09D.
4. This will bring up a link with this course. Scroll through to choose "feature topic."
5. At this point, the seminar can be chosen to view or the video related to the AFIT.
Additional training is available from the training website. Please see TECHassist 16044.18T2
Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more
information on GM Upper Engine and Fuel Injector Cleaner.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 3403
Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE).
Training (Canada)
To access the training video on AFIT, take the following path at the GMPro LMS Training Website:
1. After logging into the website, choose the link on the left side of the page titled "Catalog."
2. Then choose "Catalog Search."
3. Next, within the search box, Select Course Number - Contains - "T" then select search.
4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector
Tester" and select "View."
5. At this point, a new window will open and the program can be Launched.
Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE).
Techlink
Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel
Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following
path:
1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada).
2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service
Library of GM GlobalConnect).
3. Click on the GM Techlink Hyperlink.
4. Click on the Archives Hyperlink at GM Techlink.
- Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the
June 2006 Techlink Article.
- Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link
in the November 2006 Techlink Article.
Injector Cleaning Procedure
Notice
GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent
recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN
METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances
should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank.
Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that
exceeding the recommended cleaning solution concentration does not improve the effectiveness of
this procedure.
Important
Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned.
These vehicles should have any out of specification injectors replaced.
1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper
Engine and Fuel Injector Cleaner container into the J
35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are
using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14
oz) of regular unleaded gasoline.
2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and
Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any
other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector
Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be
repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline.
3. Be sure to follow all additional instructions provided with the tool.
4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump
relay and disconnecting the oil pressure switch
connector, if equipped.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 3404
5. Turn the ignition to the OFF position.
6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel
feed and return lines coming off the fuel rail with J
37287, J 42873 or J 42964 as appropriate for the fuel system.
7. Connect the J 35800-A to the vehicle fuel rail.
8. Pressurize the J 35800-A to 510 kPa (75 psi).
9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20
minutes.
10. Turn the ignition to the OFF position.
11. Disconnect the J 35800-A from the fuel rail.
12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped.
13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines.
14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is
flushed from the fuel rail and fuel lines.
15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N
88861012]) into the tank and advise the customer to
fill the tank.
16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend
that they add a bottle of GM Fuel System Treatment
Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should
keep the customer from having to repeat the injector cleaning procedure.
17. Road test the vehicle to verify that the customer concern has been corrected.
Parts Information
* Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder
engines.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Warranty Information (Saab U.S. Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 3405
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications
Fuel Injector: Electrical Specifications
Fuel Injector (w/J39021 or w/Tech 2) Fuel Injector Resistance............................................................
.............................................................................................................................11-14 ohms
Fuel Injector (W/CH47976) Fuel Injector Resistance...........................................................................
..............................................................................................................11-14 ohms
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications > Page 3408
Fuel Injector: Pressure, Vacuum and Temperature Specifications
The difference between any individual pressure drop and the average pressure drop should not be
more than 20 kPa (3 psi)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Page 3409
Fuel Injector: Diagrams
Component Connector End Views
Fuel Injector 1 (LH8)
Fuel Injector 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Page 3410
Fuel Injector 3 (LH8)
Fuel Injector 4 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Page 3411
Fuel Injector 5 (LH8)
Fuel Injector 6 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Page 3412
Fuel Injector 7 (LH8)
Fuel Injector 8 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Page 3413
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Testing and Inspection > Fuel Injector Diagnosis (W/CH47976)
Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (W/CH47976)
Fuel Injector Diagnosis (w/CH47976)
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category.
Circuit/System Description
The control module enables the appropriate fuel injector pulse for each cylinder. The ignition
voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by
grounding the control circuit via a solid state device called a driver. A fuel injector coil winding
resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit
DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by
temperature. The resistance of the fuel injector coil windings will increase as the temperature of the
fuel injector increases.
The CH-47976 , is used to test the fuel pump, fuel system leak down, and the fuel injectors.
Following the User Guide, CH 47976-11, and the on screen prompts or selections, will indicate the
steps required to perform each of the available tests. The tester will perform all of the tests
automatically and display results of the test. The results can also be down loaded for storage and
printing.
Reference Information Schematic Reference
Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Special Tools
CH-47976 Active Fuel Injector Tester
Component Testing
Fuel Injector Coil Test
Verify the resistance of each fuel injector with one of the following methods:
* If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of
each fuel injector should be 11-14 ohms.
‹› If the injectors measure OK, perform the Active Fuel Injector Tester (AFIT) Test Procedure. ‹› If
not within the specified range, replace the fuel injector.
* If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each
fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value.
The difference between the lowest value and the highest value should be equal to or less than 3
ohms.
‹› If the difference is equal to or less than 3 ohms, refer to AFIT Test Procedure. ‹› If the difference
is more than 3 ohms, add all of the fuel injector resistance values to obtain a total resistance value.
Divide the total resistance
value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest
individual fuel injector resistance value from the average resistance value. Compute the difference
between the highest individual fuel injector resistance value and the average resistance value.
Replace the fuel injector that displays the greatest difference above or below the average.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Testing and Inspection > Fuel Injector Diagnosis (W/CH47976) > Page 3416
Important:
* DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F).
Irregular fuel pressure readings may result due to hot soak fuel boiling.
* Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic.
AFIT Test Procedure
1. Turn OFF all accessories. 2. Turn OFF the ignition. 3. Install the AFIT. Refer to the AFIT User
Guide. 4. Turn ON the AFIT and select the vehicle. 5. Turn ON the ignition and perform the Injector
Test.
‹› If the AFIT aborts testing due to fuel pressure or fuel leak down, refer to Fuel System Diagnosis
(See: Computers and Control
Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System
Diagnosis).
6. View the test results.
‹› If any injector exceeds the recommended tolerance, replace the injector(s), E-85 only. All other
engine, refer to Fuel Injector Cleaning (See:
Service and Repair/Procedures).
Repair Instructions
Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures) after completing the diagnostic procedure.
Fuel Injector Replacement (See: Service and Repair/Removal and Replacement)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Testing and Inspection > Fuel Injector Diagnosis (W/CH47976) > Page 3417
Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (w/J39021 or w/Tech 2)
Fuel Injector Diagnosis (w/J39021 or w/Tech 2)
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category.
Circuit/System Description
The control module enables the appropriate fuel injector pulse for each cylinder. The ignition
voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by
grounding the control circuit via a solid state device called a driver. A fuel injector coil winding
resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit
DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by
temperature. The resistance of the fuel injector coil windings will increase as the temperature of the
fuel injector increases.
When performing the fuel injector balance test, the scan tool is first used to energize the fuel pump
relay. The fuel injector tester or the scan tool is then used to pulse each injector for a precise
amount of time, allowing a measured amount of the fuel to be injected. This causes a drop in the
system fuel pressure that can be recorded and used to compare each injector.
Diagnostic Aids
* Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that
is causing the condition.
* Operating the vehicle over a wide temperature range may help isolate the fuel injector that is
causing the condition.
* Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector
condition may only be apparent at a certain temperature, or under certain conditions.
Reference Information Schematic Reference
Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning)for scan
tool information Special Tools
* CH-48027 Digital Pressure Gage
* J 39021 Fuel Injector Coil and Balance Tester
* J 44602 Injector Test Adapter
Component Testing
Fuel Injector Coil Test
Verify the resistance of each fuel injector with one of the following methods:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Testing and Inspection > Fuel Injector Diagnosis (W/CH47976) > Page 3418
* If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of
each fuel injector should be 11-14 ohms.
‹› If the injectors measure OK, perform the Fuel Injector Balance Test - Fuel Pressure Test. ‹› If not
within the specified range, replace the fuel injector.
* If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each
fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value.
The difference between the lowest value and the highest value should be equal to or less than 3
ohms.
‹› If the difference is equal to or less than 3 ohms, refer to Fuel Injector Balance Test - Fuel
Pressure Test for further diagnosis of the fuel
injectors.
‹› If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a
total resistance value. Divide the total resistance
value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest
individual fuel injector resistance value from the average resistance value. Compute the difference
between the highest individual fuel injector resistance value and the average resistance value.
Replace the fuel injector that displays the greatest difference above or below the average.
Important:
*
DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F). Irregular
fuel pressure readings may result due to hot soak fuel boiling.
* Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic.
* Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
Fuel Injector Balance Test-Fuel Pressure Test
1. Install a CH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Filter/Fuel
Pressure Release/Service and Repair/Fuel
Pressure Gage Installation and Removal).
2. Turn ON the ignition, with the engine OFF.
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
3. Command the fuel pump relay ON with a scan tool. 4. Observe the fuel pressure gage with the
fuel pump commanded ON. The fuel pressure should be 345-414 kPa (50-60 psi).
‹› If the fuel pressure is not 345-414 kPa (50-60 psi), refer to Fuel System Diagnosis (See:
Computers and Control Systems/Testing and
Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis).
5. Monitor the CH-48027 for one minute. The fuel pressure should not decrease more than 34 kPa
(5 psi).
‹› If the fuel pressure decreases more than 34 kPa (5 psi), refer to Fuel System Diagnosis (See:
Computers and Control Systems/Testing and
Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis).
6. Perform the Fuel Injector Balance Test with Special Tool or the Fuel Injector Balance Test with
Tech 2.
Fuel Injector Balance Test with Special Tool
1. Set the amperage supply selector switch on the fuel injector tester to the Balance Test 0.5-2.5
amp position. 2. Connect the J 39021 to a fuel injector with a J 44602 . 3. Command the fuel pump
relay ON and then OFF three times with a scan tool. On the last command, as the fuel pressure
begins to slowly degrade
and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record
this fuel pressure. This is the starting pressure at which you will pulse each injector.
4. Command the fuel pump relay ON one more time and energize the fuel injector by depressing
the Push to Start Test button on the J 39021 at the
previously selected pressure.
5. After the injector stops pulsing, select Min from the Display Mode and record the Min pressure.
Important: New test results will not be recorded if the Min/Max results are not cleared after each
injector is tested.
6. Clear the Min/Max results. 7. Select Normal from the Display Mode. 8. Repeat steps 2 and 4
through 7 for each fuel injector. 9. Perform the Pressure Drop Calculation.
Fuel Injector Balance Test with Tech 2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Testing and Inspection > Fuel Injector Diagnosis (W/CH47976) > Page 3419
1. Command the fuel pump relay ON and then OFF three times with a scan tool. On the last
command, as the fuel pressure begins to slowly degrade
and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record
this fuel pressure. This is the starting pressure at which you will pulse each injector.
2. With a scan tool, select the Fuel Injector Balance Test function within the Special Functions
menu. 3. Select an injector to be tested. 4. Press Enter to prime the fuel system. 5. Energize the
fuel injector by depressing the Pulse Injector button on the scan tool at the previously selected
pressure. 6. After the injector stops pulsing, select Min from the Display Mode on the CH-48027
and record the Min pressure.
Important: New test results will not be recorded if the Min/Max results are not cleared after each
injector is tested.
7. Clear the Min/Max results on the CH-48027 . 8. Select Normal from the Display Mode on the
CH-48027 . 9. Press Enter on the scan tool to bring you back to the Select Injector screen.
10. Repeat steps 3 through 9 for each fuel injector. 11. Perform the Pressure Drop Calculation.
Pressure Drop Calculation
1. Subtract the minimum pressure from the starting pressure for one fuel injector. The result is the
pressure drop value. 2. Obtain a pressure drop value for each fuel injector. 3. Add all of the
individual pressure drop values except for the injector suspected of being faulty. This is the total
pressure drop. 4. Divide the total pressure drop by the number of fuel injectors that were added
together. This is the average pressure drop. The difference between
any individual pressure drop and the average pressure drop should not be more than 20 kPa (3
psi).
‹› If the difference between any individual pressure drop and the average pressure drop is more
than 20 kPa (3 psi), replace the fuel injector,
E-85 only. All other engine, refer to Fuel Injector Cleaning (See: Service and Repair/Procedures).
Repair Instructions
Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures) after completing the diagnostic procedure.
Fuel Injector Replacement (See: Service and Repair/Removal and Replacement)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Procedures
Fuel Injector: Procedures
Fuel Injector Cleaning
Special Tools
* J 37287 Fuel Line Shut-Off Adapters
* J 35800-A Fuel Injector Cleaner
* J 42873-1 3/8 Fuel Line Shut-Off Valve
* J 42873-2 5/16 Return Pipe Shut-Off Valve
* J 42964-1 3/8 Fuel Pipe Shut-Off Valve
* J 42964-2 5/16 Fuel Pipe Shut-Off Valve
Caution:
* GM Upper Engine and Fuel Injector Cleaner is the only injector cleaning agent recommended.
DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN
DAMAGE FUEL SYSTEM COMPONENTS.
* Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the
vehicle fuel tank, as it may damage the fuel pump and other system components.
* Do not exceed the recommended cleaning solution concentration. Higher concentrations may
damage fuel system components. Testing has demonstrated that exceeding the recommended
cleaning solution concentration does not improve the effectiveness of this procedure.
Note: Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors
cleaned. These vehicles should have the injectors replaced.
1. Obtain J 35800-A (2).
Note: Make sure the valve at the bottom of the canister (3) is closed.
2. For 4, 5, and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper
Engine and Fuel Injector Cleaner twin reservoir
container into the J 35800-A , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded
gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of
GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded
gasoline.
3. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and
Fuel Injector Cleaner twin reservoir container into
the J 35800-A , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you
are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper
Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This
procedure will need to be repeated for an 8 cylinder engine. The 8 cylinder engines receive 960 ml
total fluid-120 ml (4 oz) of GM Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of
gasoline.
4. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional
instructions provided with the tool. 5. Electrically disable the vehicle fuel pump by removing the fuel
pump relay and disconnecting the oil pressure switch connector, if equipped. 6. Disconnect the fuel
feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped,
coming off the fuel rail with J
37287 , or J 42964-1 , and J 42964-2 or J 42873-1 , and J 42873-2 as appropriate for the fuel
system.
7. Connect the J 35800-A to the vehicle fuel rail.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Procedures > Page 3422
8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls due to
lack of fuel. This should take approximately 15-20 minutes.
10. Turn the ignition to the OFF position. 11. Injectors should be flow-tested at this point. If further
cleaning is needed, a repeat of the above procedure should be done.
When the injector restriction returns to zero, proceed to step 12.
12. Disconnect the J 35800-A from the fuel rail. 13. Reconnect the vehicle fuel pump relay and oil
pressure switch connector, if equipped. 14. Remove the J 37287 , or J 42964-1 and J 42964-2 , or
J 42873-1 and J 42873-2 and reconnect the vehicle fuel feed and return lines. 15. Start and idle the
vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail
and fuel lines. 16. Pour the entire contents of GM Fuel System Treatment Plus, GM P/N 88861011
(Canadian P/N 88861012) into a nearly empty tank and advise the
customer to refuel with up to 76 L (20 gal) of fuel.
17. Advise the customer to use only a Top Tier Detergent gasoline and to add a bottle of GM Fuel
System Treatment Plus to the fuel tank at every oil
change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to
repeat the injector cleaning procedure.
18. Road test the vehicle to verify that the customer concern has been corrected.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Procedures > Page 3423
Fuel Injector: Removal and Replacement
Fuel Injector Replacement
Removal Procedure
Caution: Use care in removing the fuel injectors in order to prevent damage to the fuel injector
electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of
cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.
Note: The engine oil may be contaminated with fuel if the fuel injectors are leaking.
1. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (See: Fuel
Rail/Service and Repair/Fuel Injection Fuel Rail
Assembly Replacement).
2. Remove and discard the fuel injector retainer clip (4). 3. Remove the fuel injector (2). 4. Remove
and discard the fuel injector O-ring seals (1 and 3).
Installation Procedure
Note: When ordering new fuel injectors, you must order the correct injector for the application being
serviced.
The fuel injector (1) is stamped with a identification part number (2). A 4-digit build date code (3)
indicates the month (4), day (5), year (6), and the shift (7) that built the injector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Procedures > Page 3424
1. Lubricate the NEW injector O-ring seals (2 and 4) with clean engine oil. 2. Install the NEW
injector O-ring seals (2 and 4) onto the injector (3). 3. Install a NEW retainer clip (1) on the injector
(3).
4. Push the fuel injector into the fuel rail injector socket with the electrical connector facing outward.
The retainer clip locks on to a flange on the
fuel rail injector socket.
5. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (See: Fuel
Rail/Service and Repair/Fuel Injection Fuel Rail
Assembly Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module >
Component Information > Technical Service Bulletins > Recalls for Fuel Injector Control Module: > NHTSA09V154000 >
May > 09 > Recall 09V154000: Fuel System Control Module Shorting
Fuel Injector Control Module: Recalls Recall 09V154000: Fuel System Control Module Shorting
VEHICLE MAKE/MODEL: MODEL YEAR(S): Cadillac/Escalade 2009 Cadillac/Escalade ESV 2009
Cadillac/Escalade EXT 2009 Chevrolet/Avalanche 2009 Chevrolet/Colorado 2009
Chevrolet/Suburban 2009 Chevrolet/Tahoe 2009 GMC/Canyon 2009 GMC/Yukon 2009
GMC/Yukon XL 2009 MANUFACTURER: General Motors Corp.
MFR'S REPORT DATE: May 06, 2009
NHTSA CAMPAIGN ID NUMBER: 09V154000
NHTSA ACTION NUMBER: N/A COMPONENT: Fuel System, Gasoline
POTENTIAL NUMBER OF UNITS AFFECTED: 27188
SUMMARY: GM is recalling 27,188 M/Y 2009 Cadillac Escalade, Escalade Hybrid, Escalade ESV,
and Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe, Tahoe Hybrid, and Colorado; and
GMC Yukon, Yukon Hybrid, Yukon XL, and Canyon vehicles. The fuel system control modules may
have a condition in which an adhesive separation of the Room Temperature Vulcanizing (RTV)
seal between the seal and the housing may allow water to seep into the module.
CONSEQUENCE: Water in the module could cause a short or open circuit, illumination of the
service engine soon lamp, setting of diagnostic trouble codes or the engine may be hard to start,
may not start or may stall increasing the risk of a crash.
REMEDY: Dealers will install a new fuel system control module free of charge. The recall is
expected to begin on or before May 18, 2009. Owners may contact Cadillac at 1-866-982-2339,
Chevrolet at 1-800-630-2438 and GMC at 1-866-996-9463 or at www.gmownercenter.com.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Control Module: >
NHTSA09V154000 > May > 09 > Recall 09V154000: Fuel System Control Module Shorting
Fuel Injector Control Module: All Technical Service Bulletins Recall 09V154000: Fuel System
Control Module Shorting
VEHICLE MAKE/MODEL: MODEL YEAR(S): Cadillac/Escalade 2009 Cadillac/Escalade ESV 2009
Cadillac/Escalade EXT 2009 Chevrolet/Avalanche 2009 Chevrolet/Colorado 2009
Chevrolet/Suburban 2009 Chevrolet/Tahoe 2009 GMC/Canyon 2009 GMC/Yukon 2009
GMC/Yukon XL 2009 MANUFACTURER: General Motors Corp.
MFR'S REPORT DATE: May 06, 2009
NHTSA CAMPAIGN ID NUMBER: 09V154000
NHTSA ACTION NUMBER: N/A COMPONENT: Fuel System, Gasoline
POTENTIAL NUMBER OF UNITS AFFECTED: 27188
SUMMARY: GM is recalling 27,188 M/Y 2009 Cadillac Escalade, Escalade Hybrid, Escalade ESV,
and Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe, Tahoe Hybrid, and Colorado; and
GMC Yukon, Yukon Hybrid, Yukon XL, and Canyon vehicles. The fuel system control modules may
have a condition in which an adhesive separation of the Room Temperature Vulcanizing (RTV)
seal between the seal and the housing may allow water to seep into the module.
CONSEQUENCE: Water in the module could cause a short or open circuit, illumination of the
service engine soon lamp, setting of diagnostic trouble codes or the engine may be hard to start,
may not start or may stall increasing the risk of a crash.
REMEDY: Dealers will install a new fuel system control module free of charge. The recall is
expected to begin on or before May 18, 2009. Owners may contact Cadillac at 1-866-982-2339,
Chevrolet at 1-800-630-2438 and GMC at 1-866-996-9463 or at www.gmownercenter.com.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service
Fuel Line Coupler: Service and Repair Metal Collar Quick Connect Fitting Service
Metal Collar Quick Connect Fitting Service
Special Tools
J 37088-A Fuel Line Disconnect Tool Set
Removal Procedure
Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions).
1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel
Pressure Relief (With CH-48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel
Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and
Repair/Fuel Pressure Relief (Without CH-48027)).
2. Remove the retainer from the quick-connect fitting.
Warning
Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
3. Blow dirt out of the fitting using compressed air.
4. Choose the correct J 37088-A for the size of the fitting. Insert the J 37088-A into the female
connector, then push inward in order to release the
locking tabs.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3442
5. Pull the connection apart.
Caution: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial
motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean
shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs.
Clean or replace the components and assemblies as required.
6. Using a clean shop towel, wipe off the male pipe end. 7. Inspect both ends of the fitting for dirt
and burrs.
Clean or replace the components as required.
Installation Procedure
Warning
In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always
apply a few drops of clean engine oil to the male pipe ends.
This will ensure proper reconnection and prevent a possible fuel leak.
During normal operation, the O-rings located in the female connector will swell and may prevent
proper reconnection if not lubricated.
1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the quick-connect fitting together in order to snap the retaining tabs into
place.
3. Pull on both sides of the quick-connect fitting to make sure the connection is secure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3443
4. Install the retainer to the quick-connect fitting. 5. Inspect for leaks using the following procedure:
1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF, for 10
seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5.
Inspect for leaks.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3444
Fuel Line Coupler: Service and Repair Plastic Collar Quick Connect Fitting Service
Plastic Collar Quick Connect Fitting Service
Removal Procedure
Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions).
Note: There are several types of Plastic Collar Fuel and Evaporative Emission Quick Connect
Fittings used on this vehicle.
* Bartholomew (1)
* Q Release (2)
* Squeeze to Release (3)
* Sliding Retainer (4)
* Global Connect (5)
* TI Loc (6)
The following instructions apply to all of these types of Plastic Collar Quick Connect Fittings except
where indicated.
1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel
Pressure Relief (With CH-48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel
Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and
Repair/Fuel Pressure Relief (Without CH-48027)).
Warning: Refer to Safety Glasses and Compressed Air Warning (See: Service
Precautions/Technician Safety Information/Safety Glasses and Compressed Air Warning).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3445
Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (See:
Emission Control Systems/Evaporative Emissions System/Service Precautions/Vehicle Damage
Warnings/Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution).
2. Using compressed air, blow any dirt out of the quick-connect fitting.
3. This step applies to Bartholomew style connectors ONLY. Squeeze the plastic quick-connect
fitting release tabs.
4. This step applies to Q Release style connectors ONLY. Release the fitting by Pushing the tab
toward the other side of the slot in the fitting.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3446
5. This step applies to Squeeze to Release style connectors ONLY. Squeeze where indicated by
arrows on both sides of the plastic ring surrounding
the quick-connect fitting.
6. This step applies to Squeeze to Release style connectors ONLY. Push in the male side slightly
in order to slide the retainer away from the
retainers, squeeze where indicated by arrows on both sides of the plastic ring surrounding the
quick-connect fitting.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3447
7. This step applies to Sliding Retainer style connectors ONLY. Release the fitting by pressing on
one side of the release tab causing it to push in
slightly. If the tab doesn't move try pressing the tab in from the opposite side. The tab will only
move in one direction.
8. This step applies to the Global Connector style only. Push the connector toward the tube in order
to release the pressure. Press and hold down the
release mechanism, and pull the connector straight off the tube.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3448
9. This step applies to the TI Loc style only. Push the connector toward the tube in order to release
the pressure. Release the redundant latch (1) with
two fingers or a flat bladed tool. Then press and hold down the bottom release mechanism (2), and
pull the connector straight off the tube.
Quick Connect Fittings
Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions).
10. Pull the connection apart. 11. Using a clean shop towel, wipe off the male pipe end. 12. Inspect
both ends of the fitting for dirt and burrs.
Clean or replace the components as required.
Installation Procedure
Warning: Refer to Fuel Pipe Fitting Warning (See: Service Precautions/Fuel Pipe Fitting Warning).
1. Apply a few drops of clean engine oil to the male pipe end.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3449
2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to
snap into place.
3. Pull on both sides of the quick-connect fitting to make sure the connection is secure. 4. Inspect
for leaks using the following procedure:
1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF, for 10
seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5.
Inspect for leaks.
5. Apply a few drops of clean engine oil to the male pipe end. 6. Insert the tube in the connector
until the retainer snaps in place. 7. Push down on the redundant latch (1) until it is fully engaged
and snapped into position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Module
> Component Information > Diagrams
Fuel Pressure Control Module: Diagrams
Component Connector End Views
Fuel Pump Flow Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Module
> Component Information > Diagrams > Page 3453
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications
Fuel Pressure: Specifications
Fuel pressure (Ignition ON, engine OFF).............................................................................................
..............................................345-414 kPa (50-60 psi) fuel pressure should not decrease more than
34 kPa (5 psi) in 1 minute
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications > Page 3458
Fuel Pressure: Service Precautions
Relieving Fuel Pressure Warning
Warning
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in
order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small
amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications > Page 3459
Fuel Pressure: Testing and Inspection
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category.
Circuit/System Description
The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when
the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for
2 seconds unless the engine is in Crank or Run. While this voltage is being received, the FPCM
closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump
module in order to maintain the desired fuel rail pressure.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel
pump module, eliminating the need for a return pipe from the engine. A returnless fuel system
reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the
fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.
The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump
module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and
the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of the
flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump
located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel
pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the
correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow
check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed
pipe and the fuel rail in order to prevent long cranking times.
Electrical Information Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning)for scan
tool information Special Tools
* CH 48027 - Fuel Pressure Gage
* J 37287 - Fuel Line Shut-Off Adapters
Circuit/System Verification
Note: *
Inspect the fuel system for damage or external leaks before proceeding.
* Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
1. Ignition OFF, all accessories OFF, install the CH 48027 - Gage. Refer to Fuel Pressure Gage
Installation and Removal (See: Fuel Filter/Fuel
Pressure Release/Service and Repair/Fuel Pressure Gage Installation and Removal).
2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is
between 345-414 kPa (50-60 psi) and remains steady
for 5 minutes.
Circuit/System Testing
Note: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure
gage while the fuel pump is operating. Verify the
fuel pressure is between 345-414 kPa (50-60 psi).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications > Page 3460
‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel
pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the
items listed below. If all items test
normal, replace the fuel pump.
* Restricted fuel feed pipe
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
Note: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump
stops operating, the fuel pressure should stabilize and remain constant.
2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
‹› If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See:
Fuel Filter/Fuel Pressure Release/Service and
Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)).
2. Install the J 37287 - Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the
valve on the J 37287 - Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a
scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 Shut-Off Adapters. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1
minute.
‹› If the fuel pressure drops, locate and replace the leaking fuel injector.
7. If the fuel system test normal, replace the fuel pump.
3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
‹› If the fuel pressure decreases more than the specified value, replace the fuel pump.
4. Operate the vehicle within the Conditions of the customer's concern while monitoring the fuel
pressure with the CH 48027 - Gage. The fuel
pressure should not drop off during acceleration, cruise or hard cornering.
‹› If the fuel pressure drops off, test, inspect and repair the items listed below. If all items test
normal, replace the fuel sender.
* Restricted fuel feed pipe
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and
Control Systems/Testing and Inspection/Symptom
Related Diagnostic Procedures/Symptoms - Engine Controls).
Repair Instructions
Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures) after completing the diagnostic procedure.
* Fuel Hose/Pipes Replacement - Chassis (See: Fuel Return Line/Service and Repair)
* Fuel Injector Replacement (See: Fuel Injector/Service and Repair/Removal and Replacement)
* Fuel Tank Fuel Pump Module Replacement (See: Service and Repair)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Locations
Fuel Pump Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement
Fuel Rail: Service and Repair Fuel Injection Fuel Rail Assembly Replacement
Fuel Injection Fuel Rail Assembly Replacement
Removal Procedure
Note: An 8-digit identification number is located on the fuel rail. Refer to this model identification
number if servicing or part replacement is required.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel
Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel
Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)).
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Air Cleaner Housing/Air Cleaner Fresh Air
Duct/Hose/Service and Repair).
3. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute
pressure (MAP) sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3468
4. Remove the positive crankcase ventilation (PCV) foul air hose (1).
5. Remove the engine wiring harness clip (1) from the ignition coil bracket stud (2).
6. Remove the engine wiring harness clip (1) from the ignition coil bracket stud (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3469
7. Disconnect the engine wiring harness electrical connector (2) from the throttle body. 8.
Disconnect the engine wiring harness electrical connectors (1) from the fuel injectors. 9.
Disconnect the engine wiring harness electrical connector (3) from the ignition coil harness.
10. Disconnect the engine wiring harness electrical connector (1) from the generator. 11.
Disconnect the engine wiring harness electrical connector (3) from the evaporative emission
(EVAP) canister purge solenoid valve. 12. Disconnect the engine wiring harness electrical
connector (4) from the ignition coil harness.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3470
13. Disconnect the engine wiring harness electrical connectors (3) from the fuel injectors. 14.
Remove the engine wiring harness bracket nut (1). 15. Remove the engine wiring harness bracket
(2) from the stud and reposition the harness as needed. 16. Remove the EVAP canister purge
solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement (See:
Emission
Control Systems/Evaporative Emissions System/Canister Purge Solenoid/Service and Repair).
17. Disconnect the chassis fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal
Collar Quick Connect Fitting Service (See: Fuel
Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3471
18. Remove the fuel rail bolts (1). 19. Loosen but do not remove the fuel rail crossover pipe retainer
clip screws.
Caution: *
Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical
connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in
order to avoid damaging the fuel rail components.
* Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and
other contaminants from entering open pipes and passages.
Note: Before removal, clean the fuel rail with a spray type engine cleaner, GM X-30A or equivalent,
if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent.
20. Remove the fuel rail assembly (2). 21. Remove and discard the fuel injector lower O-ring seals
(3). 22. If the fuel rail is not being replaced, proceed to the installation procedure.
Disassembly Procedure
1. Remove the fuel injectors from the fuel rail. Refer to Fuel Injector Replacement (See: Fuel
Injector/Service and Repair/Removal and
Replacement).
2. Remove the service port cap and valve from the fuel rail.
Assembly Procedure
1. Install the service port cap and valve to the fuel rail. 2. Install the fuel injectors to the fuel rail.
Refer to Fuel Injector Replacement (See: Fuel Injector/Service and Repair/Removal and
Replacement).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3472
Warning
The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a
protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is
not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a
fire and personal injury from burns.
1. Lubricate NEW lower injector O-ring seals with clean engine oil. 2. Install the NEW O-ring seals
(3) onto each injector. 3. Install the fuel rail (2) to the intake manifold. 4. Apply a 5 mm (0.2 in) band
of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the fuel
rail bolts (1).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Install the fuel rail bolts (1) and tighten to 10 Nm (89 lb in). 6. Tighten the fuel rail retainer clip
screws to 3.8 Nm (34 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3473
7. Connect the chassis fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar
Quick Connect Fitting Service (See: Fuel Line
Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service).
8. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge
Solenoid Valve Replacement (See: Emission
Control Systems/Evaporative Emissions System/Canister Purge Solenoid/Service and Repair).
9. Position the engine wiring harness as needed, and install the engine wiring harness bracket (2)
to the stud.
10. Install the engine wiring harness bracket nut (1) and tighten to 9 Nm (80 lb in). 11. Connect the
engine wiring harness electrical connectors (3) to the fuel injectors.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3474
12. Connect the engine wiring harness electrical connector (4) to the ignition coil harness. 13.
Connect the engine wiring harness electrical connector (3) to the EVAP canister purge solenoid
valve. 14. Connect the engine wiring harness electrical connector (1) to the generator.
15. Connect the engine wiring harness electrical connector (3) to the ignition coil harness. 16.
Connect the engine wiring harness electrical connectors (1) to the fuel injectors. 17. Connect the
engine wiring harness electrical connector (2) to the throttle body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3475
18. Install the engine wiring harness clip (1) to the ignition coil bracket stud (2).
19. Install the engine wiring harness clip (1) to the ignition coil bracket stud (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3476
20. Install the PCV foul air hose (1).
21. Connect the engine wiring harness electrical connector (1) to the MAP sensor. 22. Install the air
cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner
Housing/Air Cleaner Fresh Air
Duct/Hose/Service and Repair).
23. Install the fuel fill cap. 24. Connect the negative battery cable. Refer to Battery Negative Cable
Disconnection and Connection (See: Starting and Charging/Battery/Battery
Cable/Service and Repair).
25. Use the following procedure in order to inspect for leaks:
1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10
seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3477
Fuel Rail: Service and Repair Fuel Injection Fuel Rail Crossover Tube Replacement
Fuel Injection Fuel Rail Crossover Tube Replacement
Removal Procedure
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel
Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel
Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)).
2. Remove the fuel rail crossover pipe retaining clip screws (1) and retainer clips (3). 3. Remove
the crossover pipe (2) from the left and right hand fuel rails. 4. Remove and discard the crossover
fuel pipe O-ring seals (4).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3478
1. Lubricate the NEW fuel rail crossover pipe O-ring seals (4) with clean engine oil. 2. Install the
NEW fuel rail crossover pipe O-ring seal (4) onto the crossover pipe (2). 3. Install the fuel rail
crossover pipe (2) to the left and right hand fuel rails. 4. Install the fuel rail crossover pipe retainer
clips (3).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: When installing the retaining clip screws for the fuel rail crossover pipe, always start the
screws by hand. This will prevent stripping of the threads on the rail.
5. Install the fuel rail retainer clip screws (1).
Tighten the screws to 3.8 Nm (34 lb in).
6. Install the fuel fill cap. 7. Connect the negative battery cable. Refer to Battery Negative Cable
Disconnection and Connection (See: Starting and Charging/Battery/Battery
Cable/Service and Repair).
8. Use the following procedure in order to inspect for leaks:
1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn OFF the ignition OFF for 10
seconds. 3. Turn ON the ignition ON, with the engine OFF. 4. Inspect for fuel leaks.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair
Fuel Return Line: Service and Repair
Fuel Hose/Pipes Replacement - Chassis
Removal Procedure Warning: Refer to Fuel and Evaporative Emission Pipe Warning (See:
Emission Control Systems/Evaporative Emissions System/Service Precautions/Technician Safety
Information).
Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions).
Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (See:
Emission Control Systems/Evaporative Emissions System/Service Precautions/Vehicle Damage
Warnings/Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution).
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel
Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel
Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)).
2. Disconnect the chassis fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal
Collar Quick Connect Fitting Service (See: Fuel
Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service).
3. Disconnect the chassis evaporative emission (EVAP) line quick connect fitting (1) from the EVAP
purge solenoid. Refer to Plastic Collar Quick
Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect
Fitting Service).
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel pipe bracket nut (3) from the
transmission stud. 6. Remove the fuel pipe bracket from the stud.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Page 3482
7. Disconnect the fuel tank fuel feed line quick connect fitting (4) from the chassis fuel feed line.
Refer to Plastic Collar Quick Connect Fitting
Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
8. Disconnect the EVAP line quick connect fitting (1) from the chassis EVAP line. Refer to Plastic
Collar Quick Connect Fitting Service (See: Fuel
Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
9. Remove the chassis fuel feed and EVAP line bracket bolt (2).
10. Lift the chassis fuel feed and EVAP line assembly (3) up in order the remove the bracket tab
from the crossmember.
11. Remove the fuel feed and EVAP line clip (4) from the fuel line bracket. 12. Remove the fuel
pipe bracket bolt (6). 13. Remove the fuel feed and EVAP pipe assembly (3) from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Page 3483
1. Install the fuel feed and EVAP pipe assembly (3) to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Position the fuel pipe bracket (5) and install the bracket bolt (6).
Tighten the bolt to 4.5 Nm (40 lb in).
3. Install the fuel feed and EVAP line clip (4) to the fuel line bracket.
4. Position the chassis fuel feed and EVAP line assembly (3) bracket tab to the crossmember. 5.
Install the chassis fuel feed and EVAP line bracket bolt (2).
Tighten the bolt to 10 Nm (89 lb in).
6. Connect the EVAP line quick connect fitting (1) to the chassis EVAP line. Refer to Plastic Collar
Quick Connect Fitting Service (See: Fuel Line
Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Page 3484
7. Connect the fuel tank fuel feed line quick connect fitting (4) to the chassis fuel feed line. Refer to
Plastic Collar Quick Connect Fitting Service (
See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
8. Install the fuel pipe bracket onto the stud. 9. Install the fuel pipe bracket nut (3) to the
transmission stud.
Tighten the nut to 9 Nm (80 lb in).
10. Lower the vehicle. 11. Connect the chassis fuel feed line quick connect fitting (2) to the fuel rail.
Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line
Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service).
12. Connect the chassis EVAP line quick connect fitting (1) to the EVAP purge solenoid. Refer to
Plastic Collar Quick Connect Fitting Service (See:
Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair
Fuel Supply Line: Service and Repair
Fuel Hose/Pipes Replacement - Chassis
Removal Procedure Warning: Refer to Fuel and Evaporative Emission Pipe Warning (See:
Emission Control Systems/Evaporative Emissions System/Service Precautions/Technician Safety
Information).
Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions).
Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (See:
Emission Control Systems/Evaporative Emissions System/Service Precautions/Vehicle Damage
Warnings/Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution).
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel
Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel
Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)).
2. Disconnect the chassis fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal
Collar Quick Connect Fitting Service (See: Fuel
Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service).
3. Disconnect the chassis evaporative emission (EVAP) line quick connect fitting (1) from the EVAP
purge solenoid. Refer to Plastic Collar Quick
Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect
Fitting Service).
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel pipe bracket nut (3) from the
transmission stud. 6. Remove the fuel pipe bracket from the stud.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 3488
7. Disconnect the fuel tank fuel feed line quick connect fitting (4) from the chassis fuel feed line.
Refer to Plastic Collar Quick Connect Fitting
Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
8. Disconnect the EVAP line quick connect fitting (1) from the chassis EVAP line. Refer to Plastic
Collar Quick Connect Fitting Service (See: Fuel
Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
9. Remove the chassis fuel feed and EVAP line bracket bolt (2).
10. Lift the chassis fuel feed and EVAP line assembly (3) up in order the remove the bracket tab
from the crossmember.
11. Remove the fuel feed and EVAP line clip (4) from the fuel line bracket. 12. Remove the fuel
pipe bracket bolt (6). 13. Remove the fuel feed and EVAP pipe assembly (3) from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 3489
1. Install the fuel feed and EVAP pipe assembly (3) to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Position the fuel pipe bracket (5) and install the bracket bolt (6).
Tighten the bolt to 4.5 Nm (40 lb in).
3. Install the fuel feed and EVAP line clip (4) to the fuel line bracket.
4. Position the chassis fuel feed and EVAP line assembly (3) bracket tab to the crossmember. 5.
Install the chassis fuel feed and EVAP line bracket bolt (2).
Tighten the bolt to 10 Nm (89 lb in).
6. Connect the EVAP line quick connect fitting (1) to the chassis EVAP line. Refer to Plastic Collar
Quick Connect Fitting Service (See: Fuel Line
Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 3490
7. Connect the fuel tank fuel feed line quick connect fitting (4) to the chassis fuel feed line. Refer to
Plastic Collar Quick Connect Fitting Service (
See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
8. Install the fuel pipe bracket onto the stud. 9. Install the fuel pipe bracket nut (3) to the
transmission stud.
Tighten the nut to 9 Nm (80 lb in).
10. Lower the vehicle. 11. Connect the chassis fuel feed line quick connect fitting (2) to the fuel rail.
Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line
Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service).
12. Connect the chassis EVAP line quick connect fitting (1) to the EVAP purge solenoid. Refer to
Plastic Collar Quick Connect Fitting Service (See:
Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair
Fuel Filler Hose: Service and Repair
Fuel Tank Filler Pipe Replacement
Removal Procedure
1. Partially drain the fuel tank below the level of the fuel fill tube. Refer to Fuel Tank Draining (See:
Service and Repair). 2. Raise and support the vehicle, high enough to access the fuel fill hose
through the wheelhouse liner. Refer to Lifting and Jacking the Vehicle (
See: Maintenance/Vehicle Lifting/Service and Repair).
3. Remove the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner
Replacement (See: Body and Frame/Fender/Rear
Fender/Rear Fender Liner/Service and Repair).
4. Remove the fuel fill hose ground strap bolt. 5. Remove the ground strap from the frame.
6. Loosen the fuel fill hose clamp (2) at the fuel tank. 7. Disconnect the evaporative emission
(EVAP) line (1) quick connect fitting from the fill tube vent line. Refer to Plastic Collar Quick
Connect
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 3495
Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting
Service).
8. Separate the fuel fill hose from the fuel tank.
9. Remove the fuel fill hose screws.
10. Remove the fuel fill hose from the vehicle. 11. Cap the open end of the fuel tank in order to
prevent system contamination.
Installation Procedure
1. Uncap the fuel tank. 2. Position the fuel fill hose to the fender.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the fuel fill hose screws and tighten to 2 Nm (18 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 3496
4. Install the fuel fill hose to the fuel tank. 5. Connect the fuel tank EVAP line (1) quick connect
fitting to the fill tube vent line. Refer to Plastic Collar Quick Connect Fitting Service (See:
Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service).
6. Tighten the fuel fill hose clamp (2) at the fuel tank to 2.5 Nm (22 lb in).
7. Install the ground strap to the frame. Ensure that the anti rotation tab is inserted into the hole in
the frame. 8. Install the fuel fill hose ground strap bolt and tighten to 9 Nm (80 lb in). 9. Install the
left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner Replacement (See:
Body and Frame/Fender/Rear
Fender/Rear Fender Liner/Service and Repair).
10. Lower the vehicle. 11. Refill the fuel tank. 12. Install the fuel fill cap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Service and Repair
Fuel Filler Neck: Service and Repair
Fuel Tank Filler Pipe Housing Replacement
Removal Procedure
1. Open the fuel filler door. 2. Remove the fuel cap. 3. Remove the fuel filler hose. Refer to Fuel
Tank Filler Hose Replacement (). 4. Remove the screws from the fuel filler pocket. 5. Remove the
fuel filler pocket from the vehicle.
Installation Procedure
1. Align the fuel filler pocket to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the screws to the fuel filler pocket and tighten to 10 Nm (89 lb in). 3. Install the fuel filler
hose. Refer to Fuel Tank Filler Hose Replacement (). 4. Install the fuel cap. 5. Close the fuel filler
door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Diagrams
Fuel Gauge Sender: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Diagrams
Fuel Tank Unit: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 3509
Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test).
Reference Information Schematic Reference
Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning) for scan
tool information Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 3510
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or
replace the battery positive cable to the underhood fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
‹› If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
‹› If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal,
and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM
for a short to ground. If the circuit tests normal, replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming
and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and
Inspection/Programming and Relearning)
* Engine Control Module Replacement (See: Computers and Control Systems/Engine Control
Module/Service and Repair)
* Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power
Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay
Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution
Relay/Service and Repair/Relay Replacement (Within an Electrical Center))
Repair Verification
1. Install any components that have been removed or replaced during diagnosis.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 3511
2. Perform any adjustment, programming, or setup procedures that are required when a
component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60
seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while
observing the powertrain relay circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See:
Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic
procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams
Fuel Pressure Control Module: Diagrams
Component Connector End Views
Fuel Pump Flow Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page 3516
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3523
Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test).
Reference Information Schematic Reference
Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning) for scan
tool information Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3524
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or
replace the battery positive cable to the underhood fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
‹› If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
‹› If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal,
and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM
for a short to ground. If the circuit tests normal, replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming
and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and
Inspection/Programming and Relearning)
* Engine Control Module Replacement (See: Computers and Control Systems/Engine Control
Module/Service and Repair)
* Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power
Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay
Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution
Relay/Service and Repair/Relay Replacement (Within an Electrical Center))
Repair Verification
1. Install any components that have been removed or replaced during diagnosis.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3525
2. Perform any adjustment, programming, or setup procedures that are required when a
component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60
seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while
observing the powertrain relay circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See:
Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic
procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument
Panel/Center Console Component Views
Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Behind the Left Side of the I/P Components
1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal
Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition
Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument
Panel/Center Console Component Views > Page 3531
Accelerator Pedal Position Sensor: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument
Panel/Center Console Component Views > Page 3532
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument
Panel/Center Console Component Views > Page 3533
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner -
Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument
Panel/Center Console Component Views > Page 3534
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument
Panel/Center Console Component Views > Page 3535
25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to
Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to
Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33
- Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3536
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3537
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP
sensor nuts. 3. Remove the APP sensor from the vehicle.
Installation Procedure
1. Position the APP sensor over the studs.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3538
2. Install the APP sensor nuts.
Tighten the APP sensor mounting nuts to 9 Nm (80 lb in).
3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure
full range of motion.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams
Air Flow Meter/Sensor: Diagrams
Component Connector End Views
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3542
Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Removal Procedure
Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not
dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do
not touch the sensing elements or allow anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct
only, to aid in installation.
1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor.
2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner
upper housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3543
Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The
arrow must point toward the engine.
1. Install the MAF/IAT sensor (2) to the air cleaner upper housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the MAF/IAT sensor screws (1).
Tighten the screws to 1.5 Nm (13 lb in).
3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Diagrams
Throttle Body: Diagrams
Component Connector End Views
Throttle Body
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair > Procedures
Throttle Body: Procedures
Throttle Learn
Throttle Learn
Description
The engine control module (ECM) learns the airflow through the throttle body to ensure the correct
idle. The learned airflow values are stored within the ECM. These values are learned to adjust for
production variation and will continuously learn during the life of the vehicle to compensate for
reduced airflow due to coking. Anytime the throttle body airflow rate changes, for example due to
cleaning or replacing, the values must be relearned.
A vehicle that had a heavily coked throttle body that has been cleaned or replaced may take
several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability
to reset all learned values back to zero. A new ECM will also have values set to zero.
The idle may be unstable or a DTC may set if the learned values do not match the actual airflow.
Conditions for Running the Throttle Learn Procedure
With Scan Tool - Reset Procedure
* DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120,
P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205,
P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606,
P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128,
P2135, P2138, or P2176 are not set.
* Ignition ON, engine OFF.
* The vehicle speed sensor (VSS) is 0 km/h (0 mph).
Without Scan Tool - Learn Procedure
* DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120,
P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205,
P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606,
P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128,
P2135, P2138, or P2176 are not set.
* The engine speed is between 450-4,000 RPM.
* The manifold absolute pressure (MAP) is greater than 5 kPa.
* The mass air flow (MAF) is greater than 2 g/s.
* The ignition 1 voltage is greater than 10 volts.
Throttle Learn
With Scan Tool - Reset Procedure
1. Ignition ON, engine OFF, with a scan tool, perform the Idle Learn Reset in Module Setup. 2.
Start the engine, monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow
Compensation value should equal 0 percent and the
engine should be idling at a normal idle speed.
3. Clear the DTCs and return to the diagnostic that referred you here.
Without Scan Tool - Learn Procedure
Important: Do NOT perform this procedure if DTCs are set. Refer to Diagnostic Trouble Code
(DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions).
1. Start and idle the engine in PARK for 3 minutes. 2. With a scan tool, monitor desired and actual
RPM. 3. The ECM will start to learn the new idle cells and Desired RPM should start to decrease.
4. Ignition OFF for 60 seconds. 5. Start and idle the engine in PARK for 3 minutes. 6. After the 3
minute run time the engine should be idling normal.
Important: During the drive cycle the check engine light may come on with idle speed DTCs. If idle
speed codes are set, clear codes so the ECM can continue to learn.
‹› If the engine idle speed has not been learned the vehicle will need to be driven at speeds above
70 km/h (44 mph) with several decelerations
and extended idles.
7. After the drive cycle, the engine should be idling normally.
‹› If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat
step 6.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair > Procedures > Page 3549
8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that
referred you here.
Throttle Body Cleaning
Throttle Body Cleaning
1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Air Cleaner Housing/Air Cleaner Fresh Air
Duct/Hose/Service and Repair).
Warning
Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the
throttle blade could cause personal injury.
Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle
valve plate.
2. Inspect the throttle body bore and the throttle valve plate for deposits. You will need to open the
throttle valve in order to inspect all surfaces.
Caution: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may
damage fuel system components.
3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM top
engine cleaner, GM P/N 1052626 (Canadian P/N
993026) or ACDelco Carburetor Tune-Up Conditioner, P/N X66-P or an equivalent product.
4. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See:
Air Cleaner Housing/Air Cleaner Fresh Air
Duct/Hose/Service and Repair).
5. Perform the throttle learn procedure. Refer to Throttle Learn (See: Computers and Control
Systems/Testing and Inspection/Component Tests and
General Diagnostics/Throttle Learn).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair > Procedures > Page 3550
Throttle Body: Removal and Replacement
Throttle Body Assembly Replacement
Removal Procedure
Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to
prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the
electronic throttle control components. Do not immerse the electronic throttle control components in
cleaning solvents of any type.
Caution: DO NOT for any reason, insert a screwdriver or other small hand tools into the throttle
body to hold open the throttle plate, as the wedge inside the throttle body could be damaged.
1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Air Cleaner Housing/Air Cleaner Fresh Air
Duct/Hose/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (2) from the throttle body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair > Procedures > Page 3551
3. Remove the throttle body bolts (538) and nuts (507). 4. Remove the throttle body (508). 5.
Remove and discard the throttle body seal (509).
Installation Procedure
1. Install a NEW throttle body gasket (509). 2. Install the throttle body (508).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the throttle body bolts (538) and nuts (507).
Tighten the bolts/nuts to 10 Nm (89 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair > Procedures > Page 3552
4. Connect the engine wiring harness electrical connector (2) to the throttle body. 5. Install the air
cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner
Housing/Air Cleaner Fresh Air
Duct/Hose/Service and Repair).
6. Perform the throttle learn procedure. Refer to Throttle Learn (See: Computers and Control
Systems/Testing and Inspection/Component Tests and
General Diagnostics/Throttle Learn).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order: Specifications
Ignition System Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Engine - Front (LH8)
1 - Throttle Body 2 - Camshaft Position (CMP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Page 3560
Camshaft Position Sensor: Diagrams
Component Connector End Views
Camshaft Position (CMP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Page 3561
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations
Crankshaft Position Sensor: Locations
Powertrain Component Views
Engine - Right Side (LH8) (5.3L)
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3565
Crankshaft Position Sensor: Diagrams
Component Connector End Views
Crankshaft Position (CKP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Service and Repair > Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and
Charging/Starting System/Starter Motor/Service and
Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP)
sensor.
3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the
engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3568
1. Install the CKP sensor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the CKP sensor bolt.
Tighten the bolt to 25 Nm (18 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the
starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting
System/Starter Motor/Service and Repair
)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position
System Variation Learn (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3569
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions) for the applicable DTC that set.
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to
Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set.
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Testing and Inspection
Ignition Cable: Testing and Inspection
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to
accurately identify conditions that may affect engine operation. Inspect for the following conditions:
1. Correct routing of the spark plug wires - Incorrect routing may cause cross-firing. 2. Any signs of
cracks or splits in the wires. 3. Inspect each boot for the following conditions:
* Tearing
* Piercing
* Arcing
* Carbon tracking
* Corroded terminal
If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace
the wire and the component connected to the wire.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Testing and Inspection > Page 3573
Ignition Cable: Service and Repair
Spark Plug Wire Replacement
Removal Procedure
1. Remove the spark plug wire from the spark plug.
* Twist each spark plug 1/2 turn.
* Pull only on the boot in order to remove the wire from each spark plug.
2. Remove the spark plug wire from the ignition coil.
* Twist each spark plug boot 1/2 turn.
* Pull only on the boot in order to remove the wires from the ignition coil.
Installation Procedure
1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3.
Inspect the wires for proper installation:
* Push sideways on each boot in order to inspect the seating.
* Reinstall any loose boot.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Coil: > 09-06-04-025A > Dec > 10 > Ignition System - Runs
Rough MIL/ON DTC P0300/P0306
Ignition Coil: Customer Interest Ignition System - Runs Rough MIL/ON DTC P0300/P0306
TECHNICAL
Bulletin No.: 09-06-04-025A
Date: December 20, 2010
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs
Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition
Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille)
Models:
2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER
H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to
GWM/IMH
Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification
section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion
System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) is illuminated.
Some customers may also comment that the engine runs rough.
The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as
current or in history, depending on which engine the vehicle is equipped with.
Upon further examination, the technician may observe evidence of water intrusion into the spark
plug recess area.
Cause
This condition may be caused by an engine being exposed to a large quantity of water, which may
result in some of the water seeping down past the vented threads of an ignition coil bolt, then
flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole,
and collecting in the spark plug recess area.
Correction
Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If
evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the
appropriate DTC procedures in SI.
1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the
affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner
Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical
connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove
the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil
Replacement in SI.
Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply
Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads.
5. Inspect for water intrusion in the spark plug recess areas.
Warning
Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
6. If any water is present, then remove the water from the spark plug recess areas with low
pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug
Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed
into the cylinder head. Refer to Spark Plug Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Coil: > 09-06-04-025A > Dec > 10 > Ignition System - Runs
Rough MIL/ON DTC P0300/P0306 > Page 3582
9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as
indicated in the illustration, and apply it to the
ignition coil bolt threads also.
10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition
Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition
coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet
duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a
scan tool.
Hood Grille Modification for HUMMER H3 Vehicles Only
Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall
#10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall
#10088A has been performed on the vehicle, DO NOT perform the following hood grille
modification.
1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille
Replacement (H3T) in SI.
2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention
clip (1) opening in the vehicle hood (all 4
sides of the rectangular slot).
3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly
against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement
(H3T) in SI.
5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme
water pressure should not be directly applied to the
edges of the hood air grille.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Coil: > 09-06-04-025A > Dec > 10 > Ignition System - Runs
Rough MIL/ON DTC P0300/P0306 > Page 3583
from other sources.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 09-06-04-025A > Dec > 10 > Ignition System
- Runs Rough MIL/ON DTC P0300/P0306
Ignition Coil: All Technical Service Bulletins Ignition System - Runs Rough MIL/ON DTC
P0300/P0306
TECHNICAL
Bulletin No.: 09-06-04-025A
Date: December 20, 2010
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs
Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition
Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille)
Models:
2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER
H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to
GWM/IMH
Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification
section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion
System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) is illuminated.
Some customers may also comment that the engine runs rough.
The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as
current or in history, depending on which engine the vehicle is equipped with.
Upon further examination, the technician may observe evidence of water intrusion into the spark
plug recess area.
Cause
This condition may be caused by an engine being exposed to a large quantity of water, which may
result in some of the water seeping down past the vented threads of an ignition coil bolt, then
flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole,
and collecting in the spark plug recess area.
Correction
Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If
evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the
appropriate DTC procedures in SI.
1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the
affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner
Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical
connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove
the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil
Replacement in SI.
Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply
Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads.
5. Inspect for water intrusion in the spark plug recess areas.
Warning
Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
6. If any water is present, then remove the water from the spark plug recess areas with low
pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug
Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed
into the cylinder head. Refer to Spark Plug Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 09-06-04-025A > Dec > 10 > Ignition System
- Runs Rough MIL/ON DTC P0300/P0306 > Page 3589
9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as
indicated in the illustration, and apply it to the
ignition coil bolt threads also.
10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition
Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition
coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet
duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a
scan tool.
Hood Grille Modification for HUMMER H3 Vehicles Only
Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall
#10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall
#10088A has been performed on the vehicle, DO NOT perform the following hood grille
modification.
1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille
Replacement (H3T) in SI.
2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention
clip (1) opening in the vehicle hood (all 4
sides of the rectangular slot).
3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly
against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement
(H3T) in SI.
5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme
water pressure should not be directly applied to the
edges of the hood air grille.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 09-06-04-025A > Dec > 10 > Ignition System
- Runs Rough MIL/ON DTC P0300/P0306 > Page 3590
from other sources.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Page 3591
Ignition Coil: Diagrams
Component Connector End Views
Ignition Coil 1 (LH8)
Ignition Coil 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Page 3592
Ignition Coil 3 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Page 3593
Ignition Coil 4 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Page 3594
Ignition Coil 5 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Page 3595
Ignition Coil 6 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Page 3596
Ignition Coil 7 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Page 3597
Ignition Coil 8 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Page 3598
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Page 3599
Ignition Coil: Service and Repair
Ignition Coil Replacement
Removal Procedure
1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement
(See: Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
2. Remove the spark plug wire from the ignition coil.
3. Disconnect the ignition coil electrical connector.
4. Remove the ignition coil bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Page 3600
5. Remove the ignition coil.
Installation Procedure
1. Install the ignition coil.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the ignition coil bolts.
Tighten the bolts to 8 Nm (71 lb in).
3. Connect the ignition coil electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Page 3601
4. Connect the spark plug wire to the ignition coil. 5. Install the intake manifold cover. Refer to
Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations
Knock Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Engine - Right Side (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 3605
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 3606
Knock Sensor: Diagrams
Component Connector End Views
Knock Sensor (KS) 1 (LH8)
Knock Sensor (KS) 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 3607
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Service and Repair > Knock Sensor 1 Replacement
Knock Sensor: Service and Repair Knock Sensor 1 Replacement
Knock Sensor 1 Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS
retaining bolt. 4. Remove the KS (2) from the engine block.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Service and Repair > Knock Sensor 1 Replacement > Page 3610
1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals
down.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Service and Repair > Knock Sensor 1 Replacement > Page 3611
Knock Sensor: Service and Repair Knock Sensor 2 Replacement
Knock Sensor 2 Replacement
Removal Procedure
1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS)
through the wheelhouse. Refer to Lifting and Jacking
the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair).
2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body
and Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS
retaining bolt. 5. Remove the KS (1) from the engine block.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Service and Repair > Knock Sensor 1 Replacement > Page 3612
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals
rearward.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left
wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and
Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Engine - Front (LH8)
1 - Throttle Body 2 - Camshaft Position (CMP) Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Page 3617
Camshaft Position Sensor: Diagrams
Component Connector End Views
Camshaft Position (CMP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Page 3618
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Powertrain Component Views
Engine - Right Side (LH8) (5.3L)
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 3622
Crankshaft Position Sensor: Diagrams
Component Connector End Views
Crankshaft Position (CKP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and
Charging/Starting System/Starter Motor/Service and
Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP)
sensor.
3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the
engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement >
Page 3625
1. Install the CKP sensor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the CKP sensor bolt.
Tighten the bolt to 25 Nm (18 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the
starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting
System/Starter Motor/Service and Repair
)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter
Motor/Service and Repair).
5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position
System Variation Learn (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement >
Page 3626
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions) for the applicable DTC that set.
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to
Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set.
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
This vehicle has two different types of ignition lock cylinders based on what type of steering column
the vehicle is equipped with. The electric power steering (EPS) option, usually found on 4 cylinder
models, and the non EPS, usually found on 6 cylinder models, use different ignition lock cylinder
designs.
Ignition Lock Cylinder
The ignition lock cylinder uses all 10 key cut positions, 1-10 when counting from the key head. The
tumbler orientations alternate in adjacent locations from side to side with 5 tumblers on each side.
Important: The ignition lock cylinder tumblers (1) are not self retaining and must be held in place if
the key is not fully inserted in the lock cylinder (2), or until the lock cylinder (2) is assembled into
the case assembly (5).
1. Hold the uncoded cylinder assembly (2) positioned so the side with the security plug (3) faces to
the left of the key head. 2. Insert one tumbler spring (7) into each of the 4 tumbler spring holes. 3.
The first tumbler (1) to be loaded will be key cut position 1, the first number in the key code. Install
this tumbler in the tumbler slot closest to the
head of the lock cylinder (2), the end where the key is inserted.
4. Advancing one tumbler slot at a time, install tumblers 3, 5, and 7 sequentially on the same side
as tumbler 1. 5. Turn the lock cylinder over and insert one tumbler spring (7) into each of the 4
tumbler spring holes on the opposite side of the lock cylinder. 6. Insert tumbler 2 into the tumbler
slot closest to the head of the lock cylinder (2), the end where the key is inserted. 7. Advancing one
tumbler slot at a time, install tumblers 4, 6, and 8 sequentially on the same side as tumbler 2. 8.
Check for correct tumbler loading by holding the tumblers (1) in position and inserting the correct
key into the lock cylinder. All tumblers (1)
should be flush with the housing of the lock cylinder.
9. Lightly lubricate the tumblers and small detent recessed areas the tumblers are in with GM
Super Lube GM P/N 12346241 or equivalent light
lithium grease.
10. Take the slide piece and insert into the rotor. Ensure "Front of Sliding Piece" is facing the front
face of the rotor. If the slide piece is installed
incorrectly, the key cannot insert into the rotor due to no access to the ramp.
11. Install the pivot pin into the actuator lever and install the actuator lever into the ignition lock
cylinder housing. Ensure that the actuator lever is
inside of the lock cylinder housing at the end close to key insertion opening. Actuator lever should
pivot on the pin against spring tension.
12. Insert the key into the coded lock cylinder (2) and hold the lock cylinder positioned so the side
with the security plug (3) faces to the left of the key
head.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 3632
13. Hold the ignition lock housing positioned so the security plug actuator lever (3) also faces to the
right of the key head. 14. Push the exposed end of the security plug actuator lever (3) toward the
center of the lock cylinder housing (1) and hold it. Insert the coded lock
cylinder (2) with the key in it into the ignition lock cylinder housing (1) until the cap is flush with the
housing.
15. Rotate the keyed lock cylinder counterclockwise slightly until it stops and detents outward
slightly. The key should be able to be removed and the
lock cylinder should remain in the housing.
16. Install the retaining clip (1) onto the coded lock cylinder where it comes out of the back of the
lock cylinder housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 3633
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Removal Procedure
1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition
Lock Cylinder Replacement). 2. Remove the multifunction turn signal switch housing. Refer to
Multifunction Turn Signal Switch Housing Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch
Housing Replacement).
3. Remove the shear bolt from the ignition lock cylinder case using a hammer and chisel. 4.
Remove the ignition lock cylinder case.
Installation Procedure
1. Install the ignition lock cylinder case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the ignition lock cylinder case bolt and tighten it until the head shears off. 3. Install the
multifunction turn signal switch. Refer to Multifunction Turn Signal Switch Housing Replacement
(See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch
Housing Replacement).
4. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock
Cylinder Replacement). 5. The passlock sensor is part of the ignition switch. If replacing the ignition
switch, a passlock relearn will be needed. Refer to Control Module
References (See: Testing and Inspection/Programming and Relearning).
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Removal Procedure
1. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
2. Turn the ignition lock cylinder to the accessory position. 3. Insert the 90 degree tip of a pick type
tool into the ignition lock cylinder access hole. 4. Push and hold the ignition lock cylinder retaining
pin down.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 3634
5. Pull the ignition lock cylinder away from the steering column.
Installation Procedure
1. Install the ignition lock cylinder by performing the following procedure:
1. Turn the ignition lock cylinder to the accessory position. 2. Push the ignition lock cylinder in until
the retaining pin locks it in place.
2. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Engine - Right Side (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Locations > Page 3638
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Locations > Page 3639
Knock Sensor: Diagrams
Component Connector End Views
Knock Sensor (KS) 1 (LH8)
Knock Sensor (KS) 2 (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Locations > Page 3640
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement
Knock Sensor: Service and Repair Knock Sensor 1 Replacement
Knock Sensor 1 Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS
retaining bolt. 4. Remove the KS (2) from the engine block.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3643
1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals
down.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3644
Knock Sensor: Service and Repair Knock Sensor 2 Replacement
Knock Sensor 2 Replacement
Removal Procedure
1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS)
through the wheelhouse. Refer to Lifting and Jacking
the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair).
2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body
and Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS
retaining bolt. 5. Remove the KS (1) from the engine block.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3645
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals
rearward.
Tighten the KS bolt to 25 Nm (18 lb ft).
2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left
wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and
Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs
Rough MIL/ON DTC P0300/P0306
Spark Plug: Customer Interest Ignition System - Runs Rough MIL/ON DTC P0300/P0306
TECHNICAL
Bulletin No.: 09-06-04-025A
Date: December 20, 2010
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs
Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition
Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille)
Models:
2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER
H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to
GWM/IMH
Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification
section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion
System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) is illuminated.
Some customers may also comment that the engine runs rough.
The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as
current or in history, depending on which engine the vehicle is equipped with.
Upon further examination, the technician may observe evidence of water intrusion into the spark
plug recess area.
Cause
This condition may be caused by an engine being exposed to a large quantity of water, which may
result in some of the water seeping down past the vented threads of an ignition coil bolt, then
flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole,
and collecting in the spark plug recess area.
Correction
Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If
evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the
appropriate DTC procedures in SI.
1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the
affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner
Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical
connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove
the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil
Replacement in SI.
Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply
Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads.
5. Inspect for water intrusion in the spark plug recess areas.
Warning
Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
6. If any water is present, then remove the water from the spark plug recess areas with low
pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug
Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed
into the cylinder head. Refer to Spark Plug Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs
Rough MIL/ON DTC P0300/P0306 > Page 3654
9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as
indicated in the illustration, and apply it to the
ignition coil bolt threads also.
10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition
Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition
coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet
duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a
scan tool.
Hood Grille Modification for HUMMER H3 Vehicles Only
Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall
#10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall
#10088A has been performed on the vehicle, DO NOT perform the following hood grille
modification.
1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille
Replacement (H3T) in SI.
2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention
clip (1) opening in the vehicle hood (all 4
sides of the rectangular slot).
3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly
against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement
(H3T) in SI.
5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme
water pressure should not be directly applied to the
edges of the hood air grille.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs
Rough MIL/ON DTC P0300/P0306 > Page 3655
from other sources.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System Runs Rough MIL/ON DTC P0300/P0306
Spark Plug: All Technical Service Bulletins Ignition System - Runs Rough MIL/ON DTC
P0300/P0306
TECHNICAL
Bulletin No.: 09-06-04-025A
Date: December 20, 2010
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs
Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition
Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille)
Models:
2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER
H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to
GWM/IMH
Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification
section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion
System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) is illuminated.
Some customers may also comment that the engine runs rough.
The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as
current or in history, depending on which engine the vehicle is equipped with.
Upon further examination, the technician may observe evidence of water intrusion into the spark
plug recess area.
Cause
This condition may be caused by an engine being exposed to a large quantity of water, which may
result in some of the water seeping down past the vented threads of an ignition coil bolt, then
flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole,
and collecting in the spark plug recess area.
Correction
Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If
evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the
appropriate DTC procedures in SI.
1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the
affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner
Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical
connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove
the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil
Replacement in SI.
Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply
Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads.
5. Inspect for water intrusion in the spark plug recess areas.
Warning
Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
6. If any water is present, then remove the water from the spark plug recess areas with low
pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug
Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed
into the cylinder head. Refer to Spark Plug Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System Runs Rough MIL/ON DTC P0300/P0306 > Page 3661
9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as
indicated in the illustration, and apply it to the
ignition coil bolt threads also.
10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition
Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition
coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet
duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a
scan tool.
Hood Grille Modification for HUMMER H3 Vehicles Only
Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall
#10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall
#10088A has been performed on the vehicle, DO NOT perform the following hood grille
modification.
1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille
Replacement (H3T) in SI.
2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention
clip (1) opening in the vehicle hood (all 4
sides of the rectangular slot).
3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly
against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement
(H3T) in SI.
5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme
water pressure should not be directly applied to the
edges of the hood air grille.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System Runs Rough MIL/ON DTC P0300/P0306 > Page 3662
from other sources.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Page 3663
Spark Plug: Specifications
Ignition System Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Page 3664
Spark Plug: Application and ID
Ignition System Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Page 3665
Spark Plug: Testing and Inspection
Spark Plug Inspection
* Verify that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications ( See: Specifications) for the correct spark plug.
* Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling - Colder plug
- Pre-ignition causing spark plug and/or engine damage - Hotter plug
* Inspect the terminal post (1) for damage.
- Inspect for a bent or broken terminal post (1)
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post should not
move.
* Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical
charge traveling across the insulator between the terminal post (1) and ground. Inspect for the
following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess are of the cylinder head for moisture, such as oil, coolant, or water.
A spark plug boot that is saturated will cause arcing to ground.
* Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack
instead of the electrodes (3,4).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Page 3666
* Inspect for evidence of improper arcing.
- Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition
System Specifications (See: Specifications). An excessively wide electrode gap can prevent correct
spark plug operation.
- Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See:
Specifications). Insufficient torque can prevent correct spark plug operation. An over torqued spark
plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
* A rattling sound indicates internal damage.
* A looses center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3,4). Deposits on the electrodes (3,4) reduce or eliminates the
gap.
- Inspect for worn or missing platinum pads on the electrodes (3,4), if equipped.
- Inspect for excessive fouling.
* Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during installation.
Visual Inspection
* Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are
normal combustion by-products from fuels with additives.
* Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions:
- Rich fuel mixtures
* Leaking fuel injectors
* Excessive fuel pressure
* Restricted air filter element
* Incorrect combustion
- Reduced ignition system voltage output
* Weak ignition coils
* Worn ignition wires
* Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that
normal combustion deposits may not burn off.
* Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white
coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity
unless they form into a glazing over the electrode.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Page 3667
Spark Plug: Service and Repair
Spark Plug Replacement
Removal Procedure
1. Remove the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition
Cable/Service and Repair). 2. Loosen the spark plug 1-2 turns. 3. Brush or using compressed air,
blow away any dirt from around the spark plug. 4. Remove the spark plug.
If removing more than one plug, place each plug in a tray marked with the corresponding cylinder
number.
Installation Procedure
1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as
needed. Refer to Ignition System Specifications (See: Specifications). 3. Hand start the spark plug
in the corresponding cylinder.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Tighten the spark plug.
Tighten the plug to 20 Nm (15 lb ft).
5. Install the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition Cable/Service
and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams
Pressure Regulating Solenoid: Diagrams
Component Connector End Views
Pressure Control (PC) Solenoid Valve (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Locations
Shift Interlock Solenoid: Locations
Instrument Panel/Center Console Component Views
Behind the Left Side of the I/P Components
1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal
Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition
Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Locations > Page 3677
Shift Interlock Solenoid: Diagrams
Component Connector End Views
Automatic Transmission Shift Lock Control Solenoid (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Locations > Page 3678
Shift Interlock Solenoid: Service and Repair
Automatic Transmission Shift Lock Control Actuator Replacement
Removal Procedure
Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the
shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic
transmission shift lock control actuator away from the steering column jacket and the cable shift
cam
assembly.
6. Remove the automatic transmission shift lock control actuator.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Locations > Page 3679
1. Firmly install the automatic transmission shift lock control actuator onto the steering column
jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control
actuator electrical connector.
3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the
neutral position) in the following way:
1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control
actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which
disengages the adjuster teeth. Slide the adjuster block (2) as far
away from the actuator as possible.
3. Lock the adjuster block (2) in place by pushing in on the tab (1).
4. Inspect the automatic transmission shift lock control actuator for the following items:
1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the
shift lever clevis is put into the park position. 2. Turn the ignition to the ON position and depress the
brake pedal to move the shift lever out of the park position. The actuator will be
energized.
3. Readjust the automatic transmission shift lock control actuator if needed.
5. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications
Shift Solenoid: Specifications
Shift Solenoid Valve State and Gear Ratio
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3685
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3686
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3687
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3688
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3689
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3690
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3691
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3692
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3693
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3694
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3695
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3696
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3697
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3698
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3699
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3700
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3701
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3702
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3703
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3704
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3705
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3706
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3707
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3708
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3709
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3710
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3711
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3712
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3713
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3714
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3715
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3716
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3717
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3718
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3719
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3720
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3721
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3722
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Diagram Information and Instructions > Page 3762
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Computers and Control Systems/Information Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
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Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
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1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
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Diagram Information and Instructions > Page 3856
Shift Solenoid: Connector Views
Component Connector End Views
1-2 Shift Solenoid (SS) Valve (M30)
2-3 Shift Solenoid (SS) Valve (M30)
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Shift Solenoid: Service and Repair
Control and Shift Solenoids Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator
is necessary only if servicing the pressure control solenoid.
2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and
Gaskets (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Accumulator/Service and Repair).
3. Disconnect all the internal wiring harness electrical connectors from the electrical components
(1-6).
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4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). 5. Remove the
pressure control solenoid (377).
Note the orientation upon removal.
6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids.
Installation Procedure
Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined
(cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as
the valve body bolts are tightened and damage may occur.
1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers.
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Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the following items:
1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug
(376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid
retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in)
4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6).
5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Accumulator/Service and Repair).
6. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
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Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to
Transmission Fluid Check (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and
General Diagnostics/Transmission Fluid Check).
Note: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
engine control module (ECM), powertrain control module (PCM) or transmission control module
(TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP
values are learned.
8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions).
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Torque Converter Clutch Solenoid: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
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Information > Diagrams > Diagram Information and Instructions > Page 3901
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Computers and Control Systems/Information Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 4030
Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 4031
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 4032
Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 4033
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 4034
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 4035
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 4036
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4037
Torque Converter Clutch Solenoid: Connector Views
Component Connector End Views
Torque Converter Clutch (TCC) Solenoid Valve (M30)
Wiring Diagram
Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 4038
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Page 4039
Torque Converter Clutch Solenoid: Service and Repair
Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and
Wiring Harness
Special Tools
J 28458 Seal Protector Retainer Installer
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter.
Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
3. Disconnect the transmission harness 20 way connector from the transmission internal harness
pass-through connector.
Depress both tabs on the connector and pull straight up. Do not pry the connector.
Note: Removal of the valve body is not necessary for the following procedure.
4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator
Assembly, Spacer Plate, and Gaskets (See:
Transmission and Drivetrain/Automatic Transmission/Transaxle/Accumulator/Service and Repair).
5. Disconnect all the internal wiring harness electrical connectors from the electrical components
(1-6).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Page 4040
6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access
one of the TCC solenoid retaining bolts.
8. Remove the TCC solenoid bolts (68).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Page 4041
9. Remove the TCC solenoid and wiring harness (66).
Turn the wiring harness over so the wiring harness hangs down.
10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the
pressure control solenoid (377).
Note the orientation upon removal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 4042
12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal
wiring harness.
13. Using J 28458 , release the pass-through electrical connector from the transmission case.
1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4
tabs retaining the connector. 3. Pull the harness connector down through the transmission case.
14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the
transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following
defects:
* Damage
* Cracked connectors
* Exposed wires
* Loose pins
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 4043
1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the
transmission. 2. Install the pass-through electrical connector to the transmission case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid
retaining bolts. 4. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 5. Tighten the
TCC solenoid retaining bolts to 11 Nm (97 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Page 4044
Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined
(cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as
the valve body bolts are tightened and damage may occur.
6. Install the following items:
1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug
(376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid
retainer (378) 7. The solenoid retainer bolt (364)
Tighten the solenoid retainer bolt to 11 Nm (97 lb in)
7. Install the TCC PWM solenoid to the control valve body. 8. Install the TCC PWM solenoid
retainer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Page 4045
9. Connect all the internal wiring harness electrical connectors to the electrical components (1-6).
10. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Accumulator/Service and Repair).
11. Connect the transmission harness 20 way connector to the transmission pass-through
connector.
Align the arrows on each half of the connector and insert straight down.
12. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) VI transmission
fluid. Refer to Transmission Fluid Check (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and
General Diagnostics/Transmission Fluid Check).
Note: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
engine control module (ECM), powertrain control module (PCM) or transmission control module
(TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP
values are learned.
15. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information
> Service and Repair
Actuator: Service and Repair
Electric Motor Actuator Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine protection shield (EPS).
Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service
and
Repair).
3. Remove the electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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> Service and Repair > Page 4050
4. Remove the electric motor actuator.
Installation Procedure
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
Note: Apply TEFLON(TM) tape to the threads of the electric actuator motor before installation.
1. Install the electric motor actuator and tighten to 22 Nm (16 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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> Service and Repair > Page 4051
2. Install the electrical connector.
3. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid Plate/Service and Repair). 4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams
Control Module: Diagrams
Component Connector End Views
Transmission Control Module (TCM) (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Page 4057
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Page 4058
Control Module: Service and Repair
Transmission Control Module Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Locations
Fluid Pressure Sensor/Switch: Locations
Powertrain Component Views
Inside the Transmission Components (M30)
36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift
Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid
Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC)
Pulse Width Modulation (PWM) Solenoid Valve
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Locations > Page 4064
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (M30)
Description Location
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Locations
Transmission Position Switch/Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Left Side of the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 4068
1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 4069
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 4070
Transmission Position Switch/Sensor: Diagrams
Component Connector End Views
Park/Neutral Position (PNP) Switch (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 4071
Transmission Position Switch/Sensor: Service and Repair
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
2. Remove the following parts: (89), (92), (88), (85) and (84)
3. Remove the manual shaft seal (82) with a screwdriver.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 4072
1. Inspect the following items:
* Manual shaft (84) for damage or burrs
* Parking lock actuator assembly (85) for damage
* Manual shift detent lever with shaft position switch assembly (88) for damage or cracks
* Manual valve link (89) for damage
* Manual shift detent lever pin (92) discard - Do NOT reuse.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the following items:
* Manual shift detent lever with shaft position switch assembly (88)
* Parking lock actuator assembly (85)
* Manual shaft (84) (model dependent)
* NEW manual shift detent lever pin (92)
* Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft).
3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams
Transmission Speed Sensor: Diagrams
Component Connector End Views
Automatic Transmission Input Shaft Speed (ISS) Sensor (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component
Information > Diagrams
Clutch Pedal Position Sensor / Switch: Diagrams
Component Connector End Views
Clutch Pedal Position (CPP) Sensor (MA5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component
Information > Diagrams > Page 4083
Clutch Pedal Position Sensor / Switch: Service and Repair
Clutch Pedal Position Switch Replacement
Removal Procedure
1. Disconnect the electrical connector (2) from the clutch pedal position switch (1).
2. Push the clutch pedal position switch retaining plate locking tabs (2) inward toward each other to
release. 3. Remove the clutch pedal position switch (3) from the clutch pedal assembly (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component
Information > Diagrams > Page 4084
1. Slide the clutch pedal position switch (3) with retaining plate (2) into the clutch pedal bracket (1),
until the locking tabs (2) are fully engaged.
2. Connect the electrical connector (2) to the clutch pedal position switch (1). 3. Complete the
following in order to adjust the clutch pedal position switch (1).
1. Push the switch fully into the bracket, allowing the switch to ratchet in the retaining plate. 2.
Depress the clutch pedal all the way to the floor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations
PROM - Programmable Read Only Memory: Technical Service Bulletins Engine/Transmission Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4089
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4090
2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4091
Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4092
PROM - Programmable Read Only Memory: Technical Service Bulletins Engine/Transmission Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026B
Date: April 07, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2010 model year and information about
retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number
09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle)
to stresses that were not tested by General Motors. It is because of these unknown stresses, and
the potential to alter reliability, durability and emissions performance, that GM has adopted a policy
that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty
coverage, to the powertrain and driveline components whenever the presence of a non-GM
(aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4093
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4094
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the
complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4095
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams
Pressure Regulating Solenoid: Diagrams
Component Connector End Views
Pressure Control (PC) Solenoid Valve (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations
Shift Interlock Solenoid: Locations
Instrument Panel/Center Console Component Views
Behind the Left Side of the I/P Components
1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal
Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition
Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4105
Shift Interlock Solenoid: Diagrams
Component Connector End Views
Automatic Transmission Shift Lock Control Solenoid (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4106
Shift Interlock Solenoid: Service and Repair
Automatic Transmission Shift Lock Control Actuator Replacement
Removal Procedure
Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the
shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic
transmission shift lock control actuator away from the steering column jacket and the cable shift
cam
assembly.
6. Remove the automatic transmission shift lock control actuator.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4107
1. Firmly install the automatic transmission shift lock control actuator onto the steering column
jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control
actuator electrical connector.
3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the
neutral position) in the following way:
1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control
actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which
disengages the adjuster teeth. Slide the adjuster block (2) as far
away from the actuator as possible.
3. Lock the adjuster block (2) in place by pushing in on the tab (1).
4. Inspect the automatic transmission shift lock control actuator for the following items:
1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the
shift lever clevis is put into the park position. 2. Turn the ignition to the ON position and depress the
brake pedal to move the shift lever out of the park position. The actuator will be
energized.
3. Readjust the automatic transmission shift lock control actuator if needed.
5. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications
Shift Solenoid: Specifications
Shift Solenoid Valve State and Gear Ratio
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Shift Solenoid: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
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Instructions > Page 4114
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4115
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4116
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4117
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4118
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4119
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4120
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4121
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4122
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Instructions > Page 4123
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4124
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4125
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4126
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Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4127
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4141
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4142
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4143
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4144
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4145
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
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Instructions > Page 4146
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4147
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4148
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
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Instructions > Page 4149
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4150
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Instructions > Page 4151
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Instructions > Page 4152
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Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4153
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
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Instructions > Page 4154
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4155
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4157
Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Instructions > Page 4163
Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
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Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
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1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
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Shift Solenoid: Connector Views
Component Connector End Views
1-2 Shift Solenoid (SS) Valve (M30)
2-3 Shift Solenoid (SS) Valve (M30)
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Shift Solenoid: Service and Repair
Control and Shift Solenoids Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator
is necessary only if servicing the pressure control solenoid.
2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and
Gaskets (See: Automatic
Transmission/Transaxle/Accumulator/Service and Repair).
3. Disconnect all the internal wiring harness electrical connectors from the electrical components
(1-6).
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4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). 5. Remove the
pressure control solenoid (377).
Note the orientation upon removal.
6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids.
Installation Procedure
Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined
(cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as
the valve body bolts are tightened and damage may occur.
1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers.
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Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the following items:
1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug
(376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid
retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in)
4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6).
5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See:
Automatic
Transmission/Transaxle/Accumulator/Service and Repair).
6. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Automatic
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Transmission/Transaxle/Service and Repair/Removal and Replacement).
7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to
Transmission Fluid Check (See: Automatic
Transmission/Transaxle/Testing and Inspection/Component Tests and General
Diagnostics/Transmission Fluid Check).
Note: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
engine control module (ECM), powertrain control module (PCM) or transmission control module
(TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP
values are learned.
8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
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Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4294
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Information and Instructions > Page 4295
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Information and Instructions > Page 4296
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4297
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Information and Instructions > Page 4298
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Information and Instructions > Page 4299
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Information and Instructions > Page 4300
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Information and Instructions > Page 4301
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Information and Instructions > Page 4302
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Information and Instructions > Page 4303
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4304
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4305
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Information and Instructions > Page 4306
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Information and Instructions > Page 4307
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Information and Instructions > Page 4308
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Information and Instructions > Page 4309
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4310
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Information and Instructions > Page 4311
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4312
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Information and Instructions > Page 4313
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4314
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Information and Instructions > Page 4315
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4316
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4317
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Information and Instructions > Page 4318
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4319
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4320
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4321
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4322
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4323
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Information and Instructions > Page 4324
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 4325
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Information and Instructions > Page 4326
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Information and Instructions > Page 4327
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Information and Instructions > Page 4328
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Information and Instructions > Page 4329
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Information and Instructions > Page 4330
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Information and Instructions > Page 4331
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Information and Instructions > Page 4332
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Information and Instructions > Page 4333
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Information and Instructions > Page 4334
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Information and Instructions > Page 4335
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Information and Instructions > Page 4336
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Information and Instructions > Page 4338
Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Information and Instructions > Page 4340
Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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Information and Instructions > Page 4418
6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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Information and Instructions > Page 4419
2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Information and Instructions > Page 4425
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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Information and Instructions > Page 4426
4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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Information and Instructions > Page 4433
1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Information and Instructions > Page 4441
17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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Information and Instructions > Page 4445
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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Information and Instructions > Page 4452
6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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Information and Instructions > Page 4453
repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Information and Instructions > Page 4454
Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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Information and Instructions > Page 4455
8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information and Instructions > Page 4456
13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Information and Instructions > Page 4458
Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information and Instructions > Page 4459
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
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Information and Instructions > Page 4460
Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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Information and Instructions > Page 4461
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
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Information and Instructions > Page 4462
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 4463
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Information and Instructions > Page 4464
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Information and Instructions > Page 4465
Torque Converter Clutch Solenoid: Connector Views
Component Connector End Views
Torque Converter Clutch (TCC) Solenoid Valve (M30)
Wiring Diagram
Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve (M30)
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Information and Instructions > Page 4466
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4467
Torque Converter Clutch Solenoid: Service and Repair
Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and
Wiring Harness
Special Tools
J 28458 Seal Protector Retainer Installer
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter.
Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
3. Disconnect the transmission harness 20 way connector from the transmission internal harness
pass-through connector.
Depress both tabs on the connector and pull straight up. Do not pry the connector.
Note: Removal of the valve body is not necessary for the following procedure.
4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator
Assembly, Spacer Plate, and Gaskets (See:
Automatic Transmission/Transaxle/Accumulator/Service and Repair).
5. Disconnect all the internal wiring harness electrical connectors from the electrical components
(1-6).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4468
6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access
one of the TCC solenoid retaining bolts.
8. Remove the TCC solenoid bolts (68).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4469
9. Remove the TCC solenoid and wiring harness (66).
Turn the wiring harness over so the wiring harness hangs down.
10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the
pressure control solenoid (377).
Note the orientation upon removal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4470
12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal
wiring harness.
13. Using J 28458 , release the pass-through electrical connector from the transmission case.
1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4
tabs retaining the connector. 3. Pull the harness connector down through the transmission case.
14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the
transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following
defects:
* Damage
* Cracked connectors
* Exposed wires
* Loose pins
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4471
1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the
transmission. 2. Install the pass-through electrical connector to the transmission case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid
retaining bolts. 4. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 5. Tighten the
TCC solenoid retaining bolts to 11 Nm (97 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4472
Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined
(cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as
the valve body bolts are tightened and damage may occur.
6. Install the following items:
1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug
(376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid
retainer (378) 7. The solenoid retainer bolt (364)
Tighten the solenoid retainer bolt to 11 Nm (97 lb in)
7. Install the TCC PWM solenoid to the control valve body. 8. Install the TCC PWM solenoid
retainer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4473
9. Connect all the internal wiring harness electrical connectors to the electrical components (1-6).
10. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See:
Automatic
Transmission/Transaxle/Accumulator/Service and Repair).
11. Connect the transmission harness 20 way connector to the transmission pass-through
connector.
Align the arrows on each half of the connector and insert straight down.
12. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) VI transmission
fluid. Refer to Transmission Fluid Check (See: Automatic
Transmission/Transaxle/Testing and Inspection/Component Tests and General
Diagnostics/Transmission Fluid Check).
Note: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
engine control module (ECM), powertrain control module (PCM) or transmission control module
(TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP
values are learned.
15. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair
Actuator: Service and Repair
Electric Motor Actuator Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine protection shield (EPS).
Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service
and
Repair).
3. Remove the electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page
4478
4. Remove the electric motor actuator.
Installation Procedure
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
Note: Apply TEFLON(TM) tape to the threads of the electric actuator motor before installation.
1. Install the electric motor actuator and tighten to 22 Nm (16 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page
4479
2. Install the electrical connector.
3. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid Plate/Service and Repair). 4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams
Pressure Regulating Solenoid: Diagrams
Component Connector End Views
Pressure Control (PC) Solenoid Valve (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations
Shift Interlock Solenoid: Locations
Instrument Panel/Center Console Component Views
Behind the Left Side of the I/P Components
1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal
Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition
Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4488
Shift Interlock Solenoid: Diagrams
Component Connector End Views
Automatic Transmission Shift Lock Control Solenoid (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4489
Shift Interlock Solenoid: Service and Repair
Automatic Transmission Shift Lock Control Actuator Replacement
Removal Procedure
Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the
shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic
transmission shift lock control actuator away from the steering column jacket and the cable shift
cam
assembly.
6. Remove the automatic transmission shift lock control actuator.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4490
1. Firmly install the automatic transmission shift lock control actuator onto the steering column
jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control
actuator electrical connector.
3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the
neutral position) in the following way:
1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control
actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which
disengages the adjuster teeth. Slide the adjuster block (2) as far
away from the actuator as possible.
3. Lock the adjuster block (2) in place by pushing in on the tab (1).
4. Inspect the automatic transmission shift lock control actuator for the following items:
1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the
shift lever clevis is put into the park position. 2. Turn the ignition to the ON position and depress the
brake pedal to move the shift lever out of the park position. The actuator will be
energized.
3. Readjust the automatic transmission shift lock control actuator if needed.
5. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications
Shift Solenoid: Specifications
Shift Solenoid Valve State and Gear Ratio
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4496
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4497
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4498
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4499
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4500
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4501
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4502
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4503
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4504
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4505
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4506
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4507
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4508
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4509
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4510
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4511
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4512
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4513
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4514
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4515
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4516
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4517
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4518
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4519
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4520
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4521
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4522
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4523
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4524
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4525
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4526
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4527
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4528
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4529
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4530
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4531
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4532
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4533
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4534
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4535
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4536
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4537
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4538
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4539
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4540
Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4541
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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4579
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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4581
6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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4582
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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4583
1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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4584
Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4585
4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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4586
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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4587
2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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4589
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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4590
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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4591
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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4598
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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4603
Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
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4605
5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
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4607
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
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4608
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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4612
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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4613
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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4616
6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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4617
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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4618
2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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4621
2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
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4622
4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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4625
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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4626
2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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4627
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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4628
4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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4629
6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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4630
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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4631
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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4632
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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4633
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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4634
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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4635
1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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4636
3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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4637
5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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4638
7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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4639
9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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4640
11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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4641
13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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4642
15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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4643
17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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4644
19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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4645
21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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4646
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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4647
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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4648
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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4649
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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4650
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
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Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
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1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
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Shift Solenoid: Connector Views
Component Connector End Views
1-2 Shift Solenoid (SS) Valve (M30)
2-3 Shift Solenoid (SS) Valve (M30)
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Shift Solenoid: Service and Repair
Control and Shift Solenoids Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Service and Repair/Removal
and Replacement).
Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator
is necessary only if servicing the pressure control solenoid.
2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and
Gaskets (See: Accumulator/Service and Repair). 3. Disconnect all the internal wiring harness
electrical connectors from the electrical components (1-6).
4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378).
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5. Remove the pressure control solenoid (377).
Note the orientation upon removal.
6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids.
Installation Procedure
Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined
(cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as
the valve body bolts are tightened and damage may occur.
1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the following items:
1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug
(376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid
retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in)
4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6).
5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See:
Accumulator/Service and Repair). 6. Install the transmission oil pan and filter. Refer to Automatic
Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and
Replacement).
7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to
Transmission Fluid Check (See: Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check).
Note: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
engine control module (ECM), powertrain control module (PCM) or transmission control module
(TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP
values are learned.
8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4676
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Instructions > Page 4677
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4678
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4679
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4680
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4681
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4682
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4683
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4684
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4685
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4686
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4687
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4688
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4689
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4690
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4691
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4692
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4693
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4694
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4695
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4696
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4697
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4698
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4699
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4700
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4701
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4702
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4703
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4704
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4705
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4706
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4707
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4708
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4709
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4710
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4711
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4712
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4713
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4714
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4715
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Instructions > Page 4716
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Instructions > Page 4722
Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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Instructions > Page 4727
may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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Instructions > Page 4735
View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Instructions > Page 4739
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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Instructions > Page 4751
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Instructions > Page 4753
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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Instructions > Page 4763
1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Instructions > Page 4764
Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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Instructions > Page 4774
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Instructions > Page 4776
Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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Instructions > Page 4797
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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Instructions > Page 4810
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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Instructions > Page 4811
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Instructions > Page 4812
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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Instructions > Page 4813
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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Instructions > Page 4814
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Instructions > Page 4818
7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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Instructions > Page 4819
9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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Instructions > Page 4820
11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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Instructions > Page 4821
13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Instructions > Page 4822
15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Instructions > Page 4823
17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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Instructions > Page 4827
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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Instructions > Page 4829
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Instructions > Page 4833
Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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Instructions > Page 4834
6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4835
repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Instructions > Page 4836
Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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Instructions > Page 4837
8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Instructions > Page 4838
13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Instructions > Page 4839
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4840
Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Instructions > Page 4841
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
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Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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Instructions > Page 4843
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
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Instructions > Page 4844
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4845
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4846
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4847
Torque Converter Clutch Solenoid: Connector Views
Component Connector End Views
Torque Converter Clutch (TCC) Solenoid Valve (M30)
Wiring Diagram
Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4848
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4849
Torque Converter Clutch Solenoid: Service and Repair
Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and
Wiring Harness
Special Tools
J 28458 Seal Protector Retainer Installer
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter.
Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal
and Replacement).
3. Disconnect the transmission harness 20 way connector from the transmission internal harness
pass-through connector.
Depress both tabs on the connector and pull straight up. Do not pry the connector.
Note: Removal of the valve body is not necessary for the following procedure.
4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator
Assembly, Spacer Plate, and Gaskets (See:
Accumulator/Service and Repair).
5. Disconnect all the internal wiring harness electrical connectors from the electrical components
(1-6).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4850
6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access
one of the TCC solenoid retaining bolts.
8. Remove the TCC solenoid bolts (68).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4851
9. Remove the TCC solenoid and wiring harness (66).
Turn the wiring harness over so the wiring harness hangs down.
10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the
pressure control solenoid (377).
Note the orientation upon removal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4852
12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal
wiring harness.
13. Using J 28458 , release the pass-through electrical connector from the transmission case.
1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4
tabs retaining the connector. 3. Pull the harness connector down through the transmission case.
14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the
transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following
defects:
* Damage
* Cracked connectors
* Exposed wires
* Loose pins
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4853
1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the
transmission. 2. Install the pass-through electrical connector to the transmission case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid
retaining bolts. 4. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 5. Tighten the
TCC solenoid retaining bolts to 11 Nm (97 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4854
Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined
(cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as
the valve body bolts are tightened and damage may occur.
6. Install the following items:
1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug
(376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid
retainer (378) 7. The solenoid retainer bolt (364)
Tighten the solenoid retainer bolt to 11 Nm (97 lb in)
7. Install the TCC PWM solenoid to the control valve body. 8. Install the TCC PWM solenoid
retainer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4855
9. Connect all the internal wiring harness electrical connectors to the electrical components (1-6).
10. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See:
Accumulator/Service and Repair).
11. Connect the transmission harness 20 way connector to the transmission pass-through
connector.
Align the arrows on each half of the connector and insert straight down.
12. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Service and Repair/Removal and
Replacement).
13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) VI transmission
fluid. Refer to Transmission Fluid Check (See: Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check).
Note: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
engine control module (ECM), powertrain control module (PCM) or transmission control module
(TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP
values are learned.
15. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair
Accumulator: Service and Repair
Accumulator Assembly, Spacer Plate, and Gaskets
Special Tools
* J 25025-B Pump and Valve Body Alignment Pin Set
* J 36850 Transjel Lubricant
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and filter.
Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal
and Replacement).
Note: The 1-2 accumulator can be removed without removing the control valve assembly.
3. Remove the control valve body. Refer to Control Valve Body Replacement (See: Valve
Body/Service and Repair). 4. Remove the accumulator cover retaining bolts. 5. Remove the 1-2
accumulator cover assembly. 6. Disassemble the 1-2 accumulator. Refer to 1-2 Accumulator
Disassemble (See: Service and Repair/Overhaul).
7. Remove the spacer plate support retaining bolts (77).
Note: Use care not to drop the following items that will be removed along with the spacer plate:
* The number 1 checkball
* The 3-4 accumulator spring
* The 3-4 accumulator pin
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair > Page 4859
8. Remove the spacer plate support (53 or 113).
Note: Do not reuse the bonded spacer plate. Replace with a NEW bonded spacer plate.
9. Remove the bonded valve body spacer plate (48), discard, do not reuse.
10. Remove the 3-4 accumulator piston (2).
Note: Some models do not use a 3-4 accumulator spring.
11. Inspect the 3-4 accumulator spring for cracks.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair > Page 4860
12. Remove the 3-4 accumulator piston seal (45) from the 3-4 accumulator piston (44). 13. Inspect
the 3-4 accumulator piston for the following defects:
* Porosity
* Cracks
* Scoring
* Nicks and scratches
Installation Procedure
1. Install a new 3-4 accumulator piston seal (45) to the 3-4 accumulator piston (44).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair > Page 4861
2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850 .
3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case.
Ensure that the 3-4 accumulator piston legs face away from the transmission case.
4. Install the J 25025-B (2, 3) to the transmission case.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair > Page 4862
5. Place the checkball (1) on the spacer plate in the location shown. 6. Place the 3-4 accumulator
spring (2) on the spacer plate.
7. Install the J-25025-5 - guide pins into the case.
Note: Do not reuse the bonded spacer plate. Replace with a NEW bonded spacer plate.
8. Place the bonded spacer plate on the case.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair > Page 4863
9. Install the spacer plate support plate (53 or 113).
10. Install the spacer plate bolts (77).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
11. Install the accumulator bolt (115), model dependent and tighten the accumulator bolt to 11 Nm
(97 lb in).
12. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure
that the checkball (1) has remained in the proper
location.
13. Assemble the 1-2 accumulator. Refer to 1-2 Accumulator Assemble (See: Service and
Repair/Overhaul). 14. Install the 1-2 accumulator. Refer to 1-2 Accumulator Installation (See:
Service and Repair/Overhaul). 15. Remove the J 25025-B from the transmission case. 16. Install
the control valve body. Refer to Control Valve Body Replacement (See: Valve Body/Service and
Repair). 17. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and
Filter Replacement (See: Service and Repair/Removal and
Replacement).
18. Lower the vehicle. 19. Fill the transmission to the proper level with DEXRON(R) VI transmission
fluid. Refer to Transmission Fluid Check (See: Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check).
Note: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
engine control module (ECM), powertrain control module (PCM) or transmission control module
(TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP
values are learned.
20. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T
> Component Information > Service and Repair
Band Apply Servo: Service and Repair
2-4 Servo (5.3L)
Special Tools
J 29714-A Servo Cover Depressor
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the front propeller shaft. Refer to
Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller
Shaft/Service and Repair/Front Propeller Shaft Replacement).
3. Remove the right catalytic converter. Refer to Catalytic Converter Replacement - Right Side
(LH8) (See: Engine, Cooling and Exhaust/Exhaust
System/Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Right Side).
4. Remove the heat shield bolts (1). 5. Remove the heat shield (2). 6. Clean away all dirt and
debris from the 2-4 servo cover area. 7. Remove a single transmission oil pan bolt.
8. Install the J 29714-A in place of the transmission oil pan bolt. 9. Tighten the bolt in order to
compress the servo cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T
> Component Information > Service and Repair > Page 4867
10. Remove the servo cover retaining ring. 11. Remove the J 29714-A .
12. Remove the servo cover and the O-ring seal. If the cover is hung up on the seal, use a pick (2)
to pull and stretch the seal (1) out of the groove. Cut
and remove the O-ring seal before removing the cover.
13. Remove the 2-4 servo from the transmission. 14. Inspect the 4th apply piston, 2-4 servo
converter, 2nd apply piston, and the servo piston inner housing for the following defects.
* Cracks
* Scoring
* Burrs and nicks
15. Disassemble the 2-4 servo if necessary. Refer to 2-4 Band Servo 2nd Apply Piston
Disassemble (See: Service and Repair/Overhaul). 16. Clean and inspect the 2-4 servo. Refer to
2-4 Band Servo Piston Pin Length Check (See: Service and Repair/Overhaul).
Installation Procedure
1. Assemble the 2-4 servo if previously disassembled. Refer to 2-4 Servo Assembly Installation
(See: Service and Repair/Overhaul). 2. Lightly lubricate the seals with clean transmission fluid. 3.
Install new seals on the servo pistons and the servo cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T
> Component Information > Service and Repair > Page 4868
4. Install the 2-4 servo assembly into the transmission. 5. Install the J 29714-A to the transmission
oil pan flange.
6. Tighten the bolt in order to compress the servo cover. 7. Install the servo cover retaining ring. 8.
Remove the J 29714-A .
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
9. Install the oil pan bolt and tighten to 11 Nm (97 lb in).
10. Install the heat shield (2). 11. Install the heat shield bolts (1) and tighten to 10 Nm (89 lb in). 12.
Install the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side (LH8) (See:
Engine, Cooling and Exhaust/Exhaust
System/Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Left Side).
13. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See:
Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T
> Component Information > Service and Repair > Page 4869
Shaft/Service and Repair/Front Propeller Shaft Replacement).
14. Lower the vehicle. 15. Fill the transmission to the proper level. Refer to Transmission Fluid
Check (See: Testing and Inspection/Component Tests and General
Diagnostics/Transmission Fluid Check).
Note: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
16. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid
Leaking From A/T Vent
Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid
Leaking From A/T Vent > Page 4878
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-036H
> Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips
Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips
INFORMATION
Bulletin No.: 01-07-30-036H
Date: January 29, 2009
Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70)
Supercede:
This bulletin is being revised to add the 2009 model year and add details regarding spacer plates.
Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle).
Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve
Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service
Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may
also describe a condition of a second, third or fourth gear start that may have the same causes but
has not set this DTC yet. Below are some tips when diagnosing this DTC:
^ This is a performance code. This means that a mechanical malfunction exists.
^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical
connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set.
^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the
spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is
important to remove the spacer plate and inspect orifice # 29 and the immediate area for the
presence of chips/debris. Also, the transmission case passage directly above this orifice and the
valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003
and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a
bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens
can help to prevent plugging of orifice # 29 caused by small debris or chips.
^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the
2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the
valves, the bore and the valve body passages.
^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer
to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on
parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition.
Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found
to be cracked, broken or leaking.
It is important to also refer to the appropriate Service Manual or Service Information (SI) for further
possible causes of this condition.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E
> Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent
Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E
> Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4888
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 01-07-30-036H >
Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips
Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips
INFORMATION
Bulletin No.: 01-07-30-036H
Date: January 29, 2009
Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70)
Supercede:
This bulletin is being revised to add the 2009 model year and add details regarding spacer plates.
Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle).
Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve
Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service
Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may
also describe a condition of a second, third or fourth gear start that may have the same causes but
has not set this DTC yet. Below are some tips when diagnosing this DTC:
^ This is a performance code. This means that a mechanical malfunction exists.
^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical
connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set.
^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the
spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is
important to remove the spacer plate and inspect orifice # 29 and the immediate area for the
presence of chips/debris. Also, the transmission case passage directly above this orifice and the
valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003
and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a
bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens
can help to prevent plugging of orifice # 29 caused by small debris or chips.
^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the
2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the
valves, the bore and the valve body passages.
^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer
to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on
parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition.
Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found
to be cracked, broken or leaking.
It is important to also refer to the appropriate Service Manual or Service Information (SI) for further
possible causes of this condition.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams
Control Module: Diagrams
Component Connector End Views
Transmission Control Module (TCM) (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Page 4897
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Page 4898
Control Module: Service and Repair
Transmission Control Module Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic
Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair
Automatic Transmission Dipstick - Dipstick Tube: Service and Repair
Transmission Fluid Filler Tube and Seal Replacement (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T
> Component Information > Service and Repair
Extension Housing: Service and Repair
Case Extension Assembly Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Support the transmission with a transmission
jack. 3. Place a drain pan under the vehicle. 4. Remove the rear propeller shaft. Refer to
One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or
Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement).
5. Remove the transmission mount. Refer to Transmission Mount Replacement (2WD) (See:
Transmission Mount/Service and Repair)Transmission
Mount Replacement (4WD) (See: Transmission Mount/Service and Repair).
6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard
the case extension O-ring seal (3).
Installation Procedure
1. Install a new case extension O-ring seal (3). 2. Install the case extension (2).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the case extension bolts (1) and tighten to 45 Nm (33 lb ft). 4. Install the transmission
mount. Refer to Transmission Mount Replacement (2WD) (See: Transmission Mount/Service and
Repair)Transmission
Mount Replacement (4WD) (See: Transmission Mount/Service and Repair).
5. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See:
Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller
Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft
Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and
Repair/Two-Piece Propeller Shaft Replacement).
6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to
the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See:
Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information
Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information
INFORMATION
Bulletin No.: 08-07-30-035B
Date: November 01, 2010
Subject: Information on Water or Ethylene Glycol in Transmission Fluid
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission
Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin
Number 08-07-30-035A (Section 07 - Transmission/Transaxle).
Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission
components and will have a negative effect on reliability and durability of these parts. Water or
ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder
during engagement or gear changes, especially during torque converter clutch engagement.
Indications of water in the ATF may include:
- ATF blowing out of the transmission vent tube.
- ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a
strawberry milkshake.
- Visible water in the oil pan.
- A milky white substance inside the pan area.
- Spacer plate gaskets that appear to be glued to the valve body face or case.
- Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not
compressed.
- Rust on internal transmission iron/steel components.
If water in the ATF has been found and the source of the water entry has not been identified, or if a
leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in
the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of
ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be
obtained and the ATF tested to make an accurate decision on the need for radiator replacement.
This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking
and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These
test kits can be obtained from:
Nelco Company
Test kits can be ordered by phone or through the website listed above. Orders are shipped
standard delivery time but can be shipped on a next day delivery basis for an extra charge. One
test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost
of the complete test kit plus shipping charges should be divided by 10 and submitted on the
warranty claim as a net item.
The transmission should be repaired or replaced based on the normal cost comparison procedure.
Important If water or coolant is found in the transmission, the following components MUST be
replaced.
- Replace all of the rubber-type seals.
- Replace all of the composition-faced clutch plates and/or bands.
- Replace all of the nylon parts.
- Replace the torque converter.
- Thoroughly clean and rebuild the transmission, using new gaskets and oil filter.
Important The following steps must be completed when repairing or replacing.
Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number
02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096
TransFlow.
- Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information > Page 4909
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
AUTOMATIC TRANSMISSION FLUID Pan Removal .........................................................................
..................................................................................................................... 4.7 liters (5.0 qts)
Overhaul ..............................................................................................................................................
................................................... 10.6 liters (11.0 qts) With 245 mm Torque Converter Dry Fill .........
..............................................................................................................................................................
................................ 8.3 liters (8.8 qts) With 258 mm Torque Converter Dry Fill ................................
..............................................................................................................................................................
......... 8.8 liters (9.3 qts)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Capacity Specifications > Page 4912
Fluid - A/T: Fluid Type Specifications
AUTOMATIC TRANSAXLE FLUID
DEXRON-VI Automatic Transmission Fluid.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Page 4913
Fluid - A/T: Testing and Inspection
Transmission Fluid Check
This procedure checks the transmission fluid level, as well as the condition of the fluid itself.
Caution: Always use the proper automatic transmission fluid listed. Using incorrect automatic
transmission fluid may damage the vehicle.
Before checking the fluid level, perform the following:
1. Start the engine and park the vehicle on a level surface. Keep the engine running. 2. Apply the
parking brake and place the shift lever in PARK (P). 3. Depress the brake pedal and move the shift
lever through each gear range, pausing for about 3 seconds in each range. Then, move the shift
lever
back to PARK (P).
4. Allow the engine to idle 500-800 RPM for at least 1 minute. Slowly release the brake pedal. 5.
Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver
Information Center (DIC) or a scan tool. 6. Using the TFT reading, determine and perform the
appropriate check procedure. If the TFT reading is not within the required temperature ranges,
allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached.
Cold Check Procedure
Note: *
Use the cold check procedure only as a reference to determine if the transmission has enough fluid
to be operated safely until a hot check procedure can be made. The hot check procedure is the
most accurate method to check the fluid level. Perform the hot check procedure at the first
opportunity.
* Use this cold check procedure to check fluid level when the TFT is between 27-32°C (80-90°F).
1. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on
the passenger's side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe
the dipstick end with a clean rag or paper towel. 3. Install the dipstick by pushing it back in the
dipstick tube all the way, wait three seconds and then pull it back out again.
Note: Always check the fluid level at least twice. Consistent readings are important to maintaining
proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to
ensure it is clean and unclogged.
4. Keep the dipstick pointing down and check both sides of the dipstick, and read the lower level.
Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick.
Refer to Fluid Condition Inspection in this procedure. 6. If the fluid level is below the COLD check
line, add only enough fluid as necessary to bring the level into the COLD line. It does not take
much
fluid, generally less than one pint (0.5L). Do not overfill.
7. If the fluid level is in the acceptable range, push the dipstick back in all the way, then flip the
handle down to lock the dipstick in place. 8. Perform a hot check at the first opportunity after the
transmission reaches a normal operating temperature between 82-93°C (180-200°F).
Hot Check Procedure
Note: Use this procedure to check the transmission fluid level when the TFT is between 82-93°C
(180-200°F). The hot check procedure is the most accurate method to check the fluid level. The hot
check should be performed at the first opportunity in order to verify the cold check. The fluid level
rises as fluid temperature increases, so it is important to ensure the transmission temperature is
within range.
1. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on
the passenger side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe the
dipstick end with a clean rag or paper towel. 3. Install the dipstick by pushing it back in the dipstick
tube all the way, wait three seconds and then pull it back out.
Note: Always check the fluid level at least twice. Consistent readings are important to maintaining
proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to
ensure it is clean and unclogged.
4. Keep the dipstick tip pointing down and check both sides of the dipstick. Read the lower level.
Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick.
Refer to Fluid Condition Inspection. 6. A safe operating fluid level is within the HOT crosshatch
band on the dipstick. If the fluid level is not within the HOT band, and the transmission
temperature is between 82-93°C (180-200°F), add or drain fluid as necessary to bring the level into
the HOT band. If the fluid level is low, add only enough fluid to bring the level into the HOT band.
Note: To assist in reaching the correct temperature range of 82-93°C (180-200°F), drive the vehicle
in second gear at no more than 65 mph until the desired temperature is reached.
7. If the fluid level is low, add only enough fluid to bring the level into the HOT band. It does not
take much fluid, generally less than one pint
(0.5L). Do not overfill. Also, if the fluid level is low, inspect the transmission for leaks. Refer to Fluid
Leak Diagnosis (See: Testing and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Page 4914
Inspection/Component Tests and General Diagnostics/Fluid Leak Diagnosis).
8. If the fluid level is in the acceptable range, push the dipstick back into the dipstick tube all the
way, and then flip the handle down to lock the
dipstick in place.
9. If applicable and if the vehicle is equipped, reset the transmission oil life monitor only if the fluid
was changed.
Fluid Condition Inspection
Inspect the fluid color. The fluid should be red or dark brown.
* If the fluid color is very dark or black and has a burnt odor, inspect the fluid and inside of the
bottom pan for excessive metal particles or other debris. A small amount of "friction" material in the
bottom pan is a "normal" condition. If large pieces and/or metal particles are noted in the fluid or
bottom pan, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs
of transmission internal damage noted, replace the fluid filter assembly, repair the oil cooler, and
flush the cooler lines.
* Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or
water contamination. Refer to Engine Coolant/Water in Transmission (See: Testing and
Inspection/Symptom Related Diagnostic Procedures/Engine Coolant/Water in Transmission).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Page 4915
Fluid - A/T: Service and Repair
Automatic Transmission Fluid and Filter Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
Note: Do not pull on the boot portion of the cable.
2. Complete the following in order to disconnect the range selector cable (3) from the transmission
range selector lever ball stud:
1. Insert a flat-bladed tool between the range selector cable end (5) and the range selector lever
(1). 2. Pry the range selector cable end (5) away from the range selector lever (1).
3. Remove the bolts securing the transmission range selector cable bracket to the transmission.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Page 4916
4. Position the transmission range selector cable bracket aside for clearance while lowering the
pan.
5. Position an appropriate container under the transmission oil pan. 6. Remove the oil pan bolts
from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8.
Lightly tap the oil pan with a rubber mallet in order to loosen the pan, allow the transmission fluid to
drain into the container.
9. Remove the remaining oil pan bolts.
10. Remove the oil pan and the gasket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Page 4917
11. Grasp firmly while pulling down with a twisting motion in order to remove the filter.
12. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use
pliers or another suitable tool to remove the seal.
Discard the seal.
13. Inspect the fluid color. 14. Inspect the filter. The filter may contain the following evidence for
root cause diagnosis:
* Bronze slivers indicating bushing wear
* Clutch material
* Steel particles
15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. All traces
of the old gasket material must be removed.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Page 4918
1. Coat the new filter seal with clean automatic transmission fluid. 2. Install the new filter seal into
the transmission case. Tap the seal into place using a suitable size socket.
3. Install the new filter into the case.
4. Install the oil pan and a new gasket.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Install the oil pan bolts and tighten alternately and evenly to 16 Nm (12 lb ft). 6. Remove the
container used to catch the used transmission fluid from under the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Page 4919
7. Position the transmission range selector cable bracket to the transmission. 8. Install the
transmission range selector cable bracket bolts and tighten to 25 Nm (18 lb ft). 9. Adjust the
automatic transmission range selector cable. Refer to Range Selector Lever Cable Adjustment
(5.3L) (See: Shift Linkage/Shift
Cable/Adjustments)Range Selector Lever Cable Adjustment (2.9L and 3.7L) (See: Shift
Linkage/Shift Cable/Adjustments).
10. Lower the vehicle. 11. Fill the transmission to the proper level with DEXRON(R) VI transmission
fluid. Refer to Transmission Fluid Check (See: Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check) and Fluid
Capacity Specifications (See: Specifications/Capacity Specifications).
12. Check the COLD fluid level reading for initial fill only. 13. Inspect the oil pan gasket for leaks.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair
Fluid Filter - A/T: Service and Repair
Automatic Transmission Fluid and Filter Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
Note: Do not pull on the boot portion of the cable.
2. Complete the following in order to disconnect the range selector cable (3) from the transmission
range selector lever ball stud:
1. Insert a flat-bladed tool between the range selector cable end (5) and the range selector lever
(1). 2. Pry the range selector cable end (5) away from the range selector lever (1).
3. Remove the bolts securing the transmission range selector cable bracket to the transmission.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Page 4923
4. Position the transmission range selector cable bracket aside for clearance while lowering the
pan.
5. Position an appropriate container under the transmission oil pan. 6. Remove the oil pan bolts
from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8.
Lightly tap the oil pan with a rubber mallet in order to loosen the pan, allow the transmission fluid to
drain into the container.
9. Remove the remaining oil pan bolts.
10. Remove the oil pan and the gasket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Page 4924
11. Grasp firmly while pulling down with a twisting motion in order to remove the filter.
12. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use
pliers or another suitable tool to remove the seal.
Discard the seal.
13. Inspect the fluid color. 14. Inspect the filter. The filter may contain the following evidence for
root cause diagnosis:
* Bronze slivers indicating bushing wear
* Clutch material
* Steel particles
15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. All traces
of the old gasket material must be removed.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Page 4925
1. Coat the new filter seal with clean automatic transmission fluid. 2. Install the new filter seal into
the transmission case. Tap the seal into place using a suitable size socket.
3. Install the new filter into the case.
4. Install the oil pan and a new gasket.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Install the oil pan bolts and tighten alternately and evenly to 16 Nm (12 lb ft). 6. Remove the
container used to catch the used transmission fluid from under the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Page 4926
7. Position the transmission range selector cable bracket to the transmission. 8. Install the
transmission range selector cable bracket bolts and tighten to 25 Nm (18 lb ft). 9. Adjust the
automatic transmission range selector cable. Refer to Range Selector Lever Cable Adjustment
(5.3L) (See: Shift Linkage/Shift
Cable/Adjustments)Range Selector Lever Cable Adjustment (2.9L and 3.7L) (See: Shift
Linkage/Shift Cable/Adjustments).
10. Lower the vehicle. 11. Fill the transmission to the proper level with DEXRON(R) VI transmission
fluid. Refer to Transmission Fluid Check (See: Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check) and Fluid
Capacity Specifications (See: Specifications/Capacity Specifications).
12. Check the COLD fluid level reading for initial fill only. 13. Inspect the oil pan gasket for leaks.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Replacement
Transmission Fluid Cooler Hose/Pipe Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Remove engine protection shield. Refer to Engine Protection Shield
Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair)
3. Disconnect the transmission fluid cooler lines (3) from the radiator. Refer to Transmission Fluid
Cooler Hose/Pipe Quick-Connect Fitting
Disconnection and Connection (See: ).
4. Remove the transmission fluid cooler lines from the retainer located on the radiator. 5. Remove
the transmission fluid cooler lines from the retainer located on the right side of the engine. 6.
Support the transmission with a transmission jack. 7. Remove the transmission support. Refer to
Transmission Support Crossmember Replacement (2WD) (See: Body and
Frame/Frame/Cross-Member/Service and Repair/Transmission Support Crossmember
Replacement)Transmission Support Crossmember Replacement (4WD) (See: Body and
Frame/Frame/Cross-Member/Service and Repair/Transmission Support Crossmember
Replacement).
8. Remove the front exhaust pipe assembly. Refer to Catalytic Converter Replacement (LLV/LLR w/2WD) ()Catalytic Converter Replacement
(LLV/LLR - w/4WD) ().
9. Carefully lower the transmission to gain access to the transmission fluid cooler line fittings.
10. Disconnect the transmission fluid cooler lines (2) from the transmission. Refer to Transmission
Fluid Cooler Hose/Pipe Quick-Connect Fitting
Disconnection and Connection (See: ).
11. Remove the transmission fluid cooler lines (1) from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4931
Caution: Ensure that the cooler line being installed has a plastic cap on each end that connects to
a quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new plastic
cap and position on to the cooler line prior to the cooler line installation.
1. Install the transmission fluid cooler lines (1) to the vehicle. 2. Install the transmission fluid cooler
lines (2) to the transmission. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting
Disconnection and Connection (See: ).
3. Raise the transmission into position. 4. Install the front exhaust pipe assembly. Refer to Catalytic
Converter Replacement (LLV/LLR - w/2WD) ()Catalytic Converter Replacement
(LLV/LLR - w/4WD) ().
5. Install the transmission support. Refer to Transmission Support Crossmember Replacement
(2WD) (See: Body and
Frame/Frame/Cross-Member/Service and Repair/Transmission Support Crossmember
Replacement)Transmission Support Crossmember Replacement (4WD) (See: Body and
Frame/Frame/Cross-Member/Service and Repair/Transmission Support Crossmember
Replacement).
6. Remove the transmission jack. 7. Install the clip that holds the transmission fluid cooler lines
together. 8. Install the transmission fluid cooler lines to the right side of the engine. 9. Install the
transmission fluid cooler line to the retainer located on the radiator.
10. Install the transmission fluid cooler lines (3) to the radiator. Refer to Transmission Fluid Cooler
Hose/Pipe Quick-Connect Fitting Disconnection
and Connection (See: ).
11. Install engine protection shield. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid Plate/Service and Repair) 12. Lower the vehicle. 13. Fill the transmission to the
proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See:
Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4932
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting
Disconnection and Connection
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
Removal Procedure
Important: Perform the following procedure when removing the retaining rings and cooler lines from
the quick connect fittings located on the radiator and/or the transmission.
1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm
(2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to
rotate the retaining ring around the quick connect fitting
until the retaining ring is out of position and can be completely removed.
3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring.
5. Pull the cooler line straight out from the quick connect fitting.
Installation Procedure
Important: *
Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion.
* Do not reuse any of the existing retaining rings that were removed from the existing quick connect
fittings. Install new retaining rings.
* Ensure the following procedures are performed when installing the new retaining rings onto the
fittings.
1. Install a new retaining ring into the quick connect fitting using the following procedure:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4933
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.
3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears
through the three slots on the fitting.
4. Do not install the new retaining ring onto the fitting by pushing the retaining ring.
5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining
ring moves freely in the fitting slots.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4934
6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick
connect fitting until a click is either heard or felt.
8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9.
Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick
connect fitting.
Important: Do not manually depress the retaining clip when installing the plastic cap.
10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when
installing the plastic cap onto the quick connect
fitting.
11. Ensure that the plastic cap is fully seated against the fitting.
12. Ensure that no gap is present between the cap and the fitting.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4935
13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting.
14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the
proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See:
Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T >
Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade
Fluid Pan: Technical Service Bulletins A/T - Fluid Pan Magnet Upgrade
INFORMATION
Bulletin No.: 08-07-30-040B
Date: May 05, 2009
Subject: Information on Normal Maintenance or Warranty Service for 4T40, 4T45, 4T65, 4L60
Automatic Transmission Oil Pan Magnet Upgrade
Models:
2002-2009 GM Passenger Cars and Light Duty Trucks Equipped With the Following
Transmissions: 4T40-E or 4T45 HYDRA-MATIC(R) Automatic Transmission (RPOs MN4, MN5,
ME7) 4T65 Transmission (RPO M15 and MN7) 4L60 Transmission and Derivatives (RPO M30 is
4L60, M32 is 4L65, M70 is 4L70)
Attention:
Do not remove the transmission oil pan unless normal maintenance or diagnosis of a customer
concern requires it.
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
add 4T65 and 4L60 transmissions. Please discard Corporate Bulletin Number 08-07-30-040A
(Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
A new transmission oil pan magnet, P/N 29535617, was released for service. The current square
transmission oil pan magnet may become saturated with normal ferrous sediment and the Pressure
Control Solenoid (PCS) is now collecting ferrous sediment, making it vary from design. For a given
current the PCS electromagnet is stronger, causing the line pressure to be less than needed.
When checking PCS line pressure (refer to Line Pressure Check in SI) and it shows that the line
pressure is lower than required (refer to Current-Amps/Line Pressure Chart in SI), for a given
current at the PCS or the transmission oil pan was removed (for either normal maintenance or
warranty service), only then should the transmission oil pan magnet be upgraded.
1. Remove and discard the original square transmission oil pan magnet and install a new one in the
current location (See graphics below for the
correct application).
2. Install the second new transmission oil pan magnet in the following location as shown in the
illustration.
4T40 & 4T45
4T65E
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T >
Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade > Page 4940
Note
Only on 4T65E, the second magnet (left) should be attached to the transmission filter.
If the magnet is attached in any other location, it may cause interference (refer to graphic above).
4L60
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T >
Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade > Page 4941
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure
Sensor/Switch, A/T > Component Information > Locations
Fluid Pressure Sensor/Switch: Locations
Powertrain Component Views
Inside the Transmission Components (M30)
36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift
Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid
Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC)
Pulse Width Modulation (PWM) Solenoid Valve
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure
Sensor/Switch, A/T > Component Information > Locations > Page 4945
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (M30)
Description Location
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T >
Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise
Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise
INFORMATION
Bulletin No.: 01-07-30-042F
Date: February 05, 2010
Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise
Models:
2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3
2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32,
M70)
Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission.
Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle).
Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin
05-07-30-012.
Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift.
During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift
can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same
torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band
applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in
the transfer case.
This is a normal condition. No repairs should be attempted.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams
Pressure Regulating Solenoid: Diagrams
Component Connector End Views
Pressure Control (PC) Solenoid Valve (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Diagrams
Control Module: Diagrams
Component Connector End Views
Transmission Control Module (TCM) (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Diagrams > Page 4957
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Diagrams > Page 4958
Control Module: Service and Repair
Transmission Control Module Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep >
08 > A/T - 4T65E Fluid Leaking From A/T Vent
Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep >
08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4967
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: >
01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent
Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: >
01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4973
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4974
Seals and Gaskets: By Symptom
Technical Service Bulletin # 01-07-30-032E Date: 080929
A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4975
For vehicles repaired under warranty, use the table.
Disclaimer
Technical Service Bulletin # 01-07-30-032E Date: 080929
A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4976
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > Manual Shift Shaft Seal Replacement
Seals and Gaskets: Service and Repair Manual Shift Shaft Seal Replacement
Manual Shift Shaft Seal Replacement
Special Tools
* J 43911 Selector Shaft Seal Remover
* J 43909 Selector Shaft Seal Installer
Removal Procedure
1. Disconnect the range selector lever cable and lever from the manual shaft. 2. Ensure that the
jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide
the seal remover tool over
the selector shaft (2) with the threaded end of the tool towards the seal.
3. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of
the seal. Use a wrench to ensure that the removal tool
is firmly attached to the seal shell.
4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the
seal that was removed.
Installation Procedure
1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the
steel case facing outward. Position the seal so that
it is starting to enter the seal bore.
2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3.
Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a
mallet to strike the J 43909 and drive the new
seal into the bore until it is seated at the bottom of the bore.
4. Connect the range selector lever cable and lever to the manual shaft. 5. Fill the transmission to
the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See:
Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > Manual Shift Shaft Seal Replacement > Page 4979
Seals and Gaskets: Service and Repair Propeller Shaft Front Slip Yoke Oil Seal Replacement
Propeller Shaft Front Slip Yoke Oil Seal Replacement
Tools Required
* J 21426 Extension Housing Seal Installer
* J 39440 Extension Housing Seal Installer (Booted Seal)
* J 36850 Transjel Lubricant
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Place a drain pan under the vehicle. 3.
Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See:
Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or
Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement).
4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the
seal from the housing. 5. Inspect the case extension housing for damage. Replace the extension
housing if necessary. Refer to Case Extension Assembly Replacement (See:
Extension Housing/Service and Repair).
Installation Procedure
1. Lubricate the inside diameter of the new seal with J 36850 .
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > Manual Shift Shaft Seal Replacement > Page 4980
Note: If installing a slip yoke (booted) type seal (34), position the drain hole (1) toward the bottom
of the transmission within the area shown
2. Use the J 21426 for a standard seal or J 39440 for a booted type seal with a soft faced mallet to
install the seal. 3. Install the seal to the extension housing. 4. Install the rear propeller shaft. Refer
to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller
Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft
Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and
Repair/Two-Piece Propeller Shaft Replacement).
5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with
DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations
Fluid Pressure Sensor/Switch: Locations
Powertrain Component Views
Inside the Transmission Components (M30)
36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift
Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid
Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC)
Pulse Width Modulation (PWM) Solenoid Valve
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4985
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (M30)
Description Location
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations
Transmission Position Switch/Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Left Side of the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4989
1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4990
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4991
Transmission Position Switch/Sensor: Diagrams
Component Connector End Views
Park/Neutral Position (PNP) Switch (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4992
Transmission Position Switch/Sensor: Service and Repair
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Service and Repair/Removal
and Replacement).
2. Remove the following parts: (89), (92), (88), (85) and (84)
3. Remove the manual shaft seal (82) with a screwdriver.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4993
1. Inspect the following items:
* Manual shaft (84) for damage or burrs
* Parking lock actuator assembly (85) for damage
* Manual shift detent lever with shaft position switch assembly (88) for damage or cracks
* Manual valve link (89) for damage
* Manual shift detent lever pin (92) discard - Do NOT reuse.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the following items:
* Manual shift detent lever with shaft position switch assembly (88)
* Parking lock actuator assembly (85)
* Manual shaft (84) (model dependent)
* NEW manual shift detent lever pin (92)
* Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft).
3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Service and Repair/Removal and
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams
Transmission Speed Sensor: Diagrams
Component Connector End Views
Automatic Transmission Input Shaft Speed (ISS) Sensor (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock Solenoid > Component Information > Locations
Shift Interlock Solenoid: Locations
Instrument Panel/Center Console Component Views
Behind the Left Side of the I/P Components
1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal
Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition
Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock Solenoid > Component Information > Locations > Page 5004
Shift Interlock Solenoid: Diagrams
Component Connector End Views
Automatic Transmission Shift Lock Control Solenoid (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock Solenoid > Component Information > Locations > Page 5005
Shift Interlock Solenoid: Service and Repair
Automatic Transmission Shift Lock Control Actuator Replacement
Removal Procedure
Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the
shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic
transmission shift lock control actuator away from the steering column jacket and the cable shift
cam
assembly.
6. Remove the automatic transmission shift lock control actuator.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock Solenoid > Component Information > Locations > Page 5006
1. Firmly install the automatic transmission shift lock control actuator onto the steering column
jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control
actuator electrical connector.
3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the
neutral position) in the following way:
1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control
actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which
disengages the adjuster teeth. Slide the adjuster block (2) as far
away from the actuator as possible.
3. Lock the adjuster block (2) in place by pushing in on the tab (1).
4. Inspect the automatic transmission shift lock control actuator for the following items:
1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the
shift lever clevis is put into the park position. 2. Turn the ignition to the ON position and depress the
brake pedal to move the shift lever out of the park position. The actuator will be
energized.
3. Readjust the automatic transmission shift lock control actuator if needed.
5. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Specifications
Shift Solenoid: Specifications
Shift Solenoid Valve State and Gear Ratio
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Component Information > Diagrams > Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5177
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5178
Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5179
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5180
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5181
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5182
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5183
Shift Solenoid: Connector Views
Component Connector End Views
1-2 Shift Solenoid (SS) Valve (M30)
2-3 Shift Solenoid (SS) Valve (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5184
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5185
Shift Solenoid: Service and Repair
Control and Shift Solenoids Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Service and Repair/Removal
and Replacement).
Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator
is necessary only if servicing the pressure control solenoid.
2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and
Gaskets (See: Accumulator/Service and Repair). 3. Disconnect all the internal wiring harness
electrical connectors from the electrical components (1-6).
4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5186
5. Remove the pressure control solenoid (377).
Note the orientation upon removal.
6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids.
Installation Procedure
Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined
(cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as
the valve body bolts are tightened and damage may occur.
1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5187
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the following items:
1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug
(376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid
retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in)
4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6).
5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See:
Accumulator/Service and Repair). 6. Install the transmission oil pan and filter. Refer to Automatic
Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and
Replacement).
7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to
Transmission Fluid Check (See: Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check).
Note: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
engine control module (ECM), powertrain control module (PCM) or transmission control module
(TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP
values are learned.
8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Service and Repair
Shifter A/T: Service and Repair
Shift Lever Replacement
Removal Procedure
Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning).
1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling
(See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair).
2. Disengage the shift lever seal (2) from the steering column trim covers (1) and slide it up the shift
lever (4). 3. Remove the shift lever bolt (3) from the shift lever (4). 4. Remove the shift lever with
the shift lever seal from the steering column. 5. Transfer any parts as needed.
Installation Procedure
1. Install the shift lever with the shift lever seal to the steering column.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the shift lever bolt (3).
Tighten the bolt to 20 Nm (15 lb ft).
3. Align and secure the shift lever seal (2) to the steering column trim covers (1). 4. Enable the SIR
system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments
Shift Cable: Adjustments
Range Selector Lever Cable Adjustment (5.3L)
Adjustment Procedure
1. Ensure that the shift control is in the park (P) position. 2. Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Ensure
that the range selector cable is not restricted.
4. Pull back the plastic cover (1) on the center connector.
5. Pull up on the center tabs of the lock button (2).
Important: This step must be performed correctly to avoid a misadjusted cable. Do not grasp the
shift cable end (2) during this procedure.
6. Release the shift cable end (2) and allow the spring to tension/adjust the shift cable system. 7.
Pull the cover (3) on the shift cable end (1) back.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 5195
8. Push the lock button (2) down to engage the locking teeth on the shift cable end (1).
9. Release the cover (1).
10. Verify the cover (1) conceals the lock (2). 11. If the cover (1) does not conceal the lock (2), the
shift cable must be readjusted. 12. Lower the vehicle. 13. Check the vehicle for proper operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement
Shift Cable: Service and Repair Range Selector Lever Cable Replacement
Range Selector Lever Cable Replacement (5.3L)
Note: The range selector cable can be disassembled and removed as two independent sections
when removal of the complete cable is not necessary, or the cable can remain together and be
removed as one piece not requiring disassembly of the cable.
Disassembling Cable
1. Set the parking brake. 2. Ensure that the shift control lever is in the park (P) position. 3. Raise
and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair).
4. Pull back the spring loaded cover (2) to expose the cable adjustment lock (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5198
5. Lift the cable adjustment lock (3) up to unlock both halves of the range selector cable (1, 4).
6. Rotate the range selector cable to expose the retaining clip (5).
It may be necessary to pull the transaxle end of the range selector cable (4) out of the shift control
end of the range selector cable (1) to fully expose the retaining clip (5).
7. Remove the retaining clip (2) from the range selector cable (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5199
8. Separate the shift control end of the cable (1) from the transmission end of the cable (3).
Cable Removal - Transmission End
1. Remove the range selector cable retainers (2) from the frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5200
2. Remove the heat shield bolts (1). 3. Remove the heat shield (2).
Note: Do not pull on the boot portion of the cable.
4. Disconnect the range selector cable end (3) from the range selector lever. 5. Remove the
retainer (1) from the range selector cable (2). 6. Push the range selector cable locking tabs (2)
inward toward each other to release the cable from the bracket.
Cable Removal - Shift Control End
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5201
1. Push the cable grommet (2) and cable (1) up through the floor panel. 2. Lower the vehicle. 3.
Remove the left hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Left
Side (See: Body and Frame/Interior Moulding
/ Trim/Trim Panel/Service and Repair).
4. Pull the drivers side carpet up, enough to access the range selector cable.
5. Disconnect the range selector cable retainer (1) from the lower dash panel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5202
6. Complete the following in order to disconnect the range selector cable (4) from the transmission
range selector lever ball stud (1).
1. Insert a flat bladed tool between the range selector cable end (2) and the range selector lever. 2.
Pry the range selector cable end (2) away from the range selector lever.
7. Remove the retainer (3) from the range selector cable (4). 8. Push the range selector cable
locking tabs inward toward each other to release from the steering column bracket (5). 9. Remove
the range selector cable (4) from the vehicle.
Cable Installation - Shift Control End
1. Install the range selector cable (4) to the steering column bracket (5). 2. Install the retainer (3) to
the range selector cable (4). 3. Push the range selector cable end (2) onto the range selector lever
ball stud (1) to secure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5203
4. Connect the range selector cable retainer (2) to the lower dash panel (1).
5. Push the range selector cable down through the floor panel (2) and seat the cable grommet (1).
6. Reposition the drivers side carpet to the floor panel. 7. Inspect below the accelerator pedal for
binding, to ensure full range of motion. 8. Install the left hinge pillar trim panel. Refer to Body Hinge
Pillar Trim Panel Replacement - Left Side (See: Body and Frame/Interior Moulding /
Trim/Trim Panel/Service and Repair).
9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
Cable Installation - Transaxle End
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
Note: Ensure the range selector cable is routed exactly as originally positioned in the vehicle to
avoid coming into contact with potential hazards such as hot, sharp, and moving objects.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5204
2. Install the range selector cable (2) to the range selector cable bracket. Ensure the range selector
cable retaining tabs fully engage the range selector
cable bracket.
3. Install the retainer (1) to the range selector cable (2). 4. Connect the range selector cable end (3)
to the transaxle range switch lever.
5. Install the heat shield (2).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the heat shield bolts (1) and tighten to 10 Nm (89 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5205
7.
Install the range selector cable retainers (2) to the frame.
Assembling Cable
1. Install the cable retaining clip (2). 2. Push the transaxle end of the range selector cable (4) into
the shift control end of the range selector cable (1) until the cable retaining clip (5) is
fully locked into the range selector cable groove (3).
3. Ensure that the shift control lever and the transaxle range select lever are both in the park (P)
position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5206
4. Ensure the transaxle cable end (4) is not being held and that the spring is allowed to tension the
cable. 5. Depress the cable adjustment lock (3) in order to lock both halves of the range selector
cable (1, 4).
6. Release the spring loaded cover (2) allowing it to cover the cable adjustment lock. 7. Adjust the
automatic transmission range selector cable. Refer to Range Selector Lever Cable Adjustment
(5.3L) (See: Adjustments)Range
Selector Lever Cable Adjustment (2.9L and 3.7L) (See: Adjustments).
8. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5207
Shift Cable: Service and Repair Range Selector Lever Cable Bracket Replacement
Range Selector Lever Cable Bracket Replacement (5.3L)
Removal Procedure
1. Ensure the vehicle is in the PARK position. 2. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair).
3. Disconnect the transmission vent hose retainer (4) from the transmission range selector cable
bracket.
4. Remove the heat shield bolts (1). 5. Remove the heat shield (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5208
Note: Do not pull on the boot portion of the cable.
6. Disconnect the range selector cable end (3) from the range selector lever. 7. Remove the
retainer (1) from the range selector cable (2). 8. Push the range selector cable locking tabs (2)
inward toward each other to release the cable from the bracket.
9. Remove the bolts securing the transmission range selector cable bracket to the transmission.
10. Remove the transmission range selector cable bracket from the transmission.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5209
1. Position the transmission range selector cable bracket to the transmission.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the transmission range selector cable bracket bolts and tighten to 25 Nm (18 lb ft).
3. Install the range selector cable (2) to the range selector cable bracket. Ensure the range selector
cable retaining tabs fully engage the range selector
cable bracket.
4. Install the retainer (1) to the range selector cable (2). 5. Connect the range selector cable end (3)
to the transaxle range switch lever.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5210
6. Install the heat shield (2). 7. Install the heat shield bolts (1) and tighten to 10 Nm (89 lb in).
8. Connect the transmission vent hose retainer (4) to the transmission range selector cable
bracket. 9. Adjust the automatic transmission range selector cable. Refer to Range Selector Lever
Cable Adjustment (5.3L) (See: Adjustments)Range
Selector Lever Cable Adjustment (2.9L and 3.7L) (See: Adjustments).
10. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information
Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information
INFORMATION
Bulletin No.: 01-07-30-010C
Date: May 12, 2008
Subject: Automatic Transmission/Transaxle Torque Converter Replacement
Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009
and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75)
2009 and Prior Saab 9-7X
with ALL Automatic Transmissions and Transaxles
Supercede:
This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin
Number 01-07-30-010B (Section 07 - Transmission/Transaxle).
The purpose of this bulletin is to help technicians determine when a torque converter should be
replaced. Below is a list of general guidelines to follow.
The converter should NOT be replaced if the following apply:
^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition
(i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical
concern within the torque converter.
^ The fluid has an odor or is discolored but no evidence of metal contamination.
^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is
not harmful to the torque converter.
^ The vehicle has been exposed to high mileage.
^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter
(RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither
the converter nor the front pump assembly should be replaced.
The torque converter should be replaced under any of the following conditions:
^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic
diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the
converter bushing and/or internal 0-ring may be damaged.
^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support
and bearing or metal chips/debris in the converter.
^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines.
^ External leaks in the hub weld area lug weld or closure weld.
^ Converter pilot is broken damaged or fits poorly into the crankshaft.
^ The converter hub is scored or damaged.
^ The transmission oil is contaminated with engine coolant engine oil or water.
^ If excessive end play is found after measuring the converter for proper end play (refer to Service
Manual).
^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit
are worn or damaged. This indicates that the material came from the converter.
^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by
following Converter Vibration Procedures.
^ Blue converter or dark circular ring between lugs. This condition will also require a complete
cleaning of the cooler and a check for adequate flow
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 5215
through the cooler.
^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at
idle. The noise is gone in Neutral and Park.
^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY).
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Check Valve > Component Information > Service and Repair
Torque Converter Check Valve: Service and Repair
Torque Converter Clutch Valve and Spring Replacement
Removal Procedure
1. Remove the transmission filter. Refer to Automatic Transmission Fluid and Filter Replacement
(See: Service and Repair/Removal and
Replacement).
2. Disconnect the torque converter clutch (TCC) pulse width modulation (PWM) solenoid electrical
connector. 3. Remove the TCC PWM solenoid retainer. 4. Remove the TCC PWM solenoid in
order to access the TCC control solenoid bolts.
5. Disconnect the TCC control solenoid connector. 6. Remove the TCC control solenoid retaining
bolts. 7. Remove the TCC control solenoid.
Warning
Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal
injury could result.
8. Remove the TCC valve retainer ring (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Check Valve > Component Information > Service and Repair > Page 5219
9. Remove the following parts:
* The valve bore plug
* The TCC valve
* The TCC valve spring(s)
Installation Procedure
Note: *
Clean and inspect the TCC solenoid O-ring for cuts, nicks, and damage. Replace if necessary.
* Inspect the TCC bore for sediment and debris. Flush the bore if necessary.
* Clean and inspect the TCC valve for binding, scoring, and damage.
* Inspect the TCC spring for cracks and deformed or broken coils.
1. Install the following parts:
* The TCC valve spring
* The TCC valve
* The valve bore plug
2. Install the TCC valve retainer ring (1). 3. Install the TCC control solenoid. 4. Install the TCC
control solenoid retaining bolts and tighten to 8-14 Nm (71-124 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Check Valve > Component Information > Service and Repair > Page 5220
5. Connect the TCC control solenoid connector. 6. Install the TCC PWM solenoid. 7. Install the
TCC PWM solenoid retainer.
8. Connect the TCC PWM Solenoid electrical connector. 9. Install the transmission filter. Refer to
Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5231
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5232
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5233
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5234
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5235
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5236
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5237
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5238
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5239
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5240
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5241
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5242
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5243
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5244
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5245
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5246
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5247
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5248
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5249
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5250
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5251
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5252
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5253
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5254
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5255
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5256
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5257
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5258
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5259
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5260
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5261
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5262
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5263
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5264
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5265
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5266
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5267
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5268
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5269
Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5271
Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5272
* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5288
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5289
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5293
9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5295
5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5296
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5299
* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5306
Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5318
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5327
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5331
1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5342
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5353
8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5385
Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5386
8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5387
13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5388
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5389
Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5390
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5391
Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5392
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5393
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5394
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5395
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5396
Torque Converter Clutch Solenoid: Connector Views
Component Connector End Views
Torque Converter Clutch (TCC) Solenoid Valve (M30)
Wiring Diagram
Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5397
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Page 5398
Torque Converter Clutch Solenoid: Service and Repair
Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and
Wiring Harness
Special Tools
J 28458 Seal Protector Retainer Installer
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter.
Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal
and Replacement).
3. Disconnect the transmission harness 20 way connector from the transmission internal harness
pass-through connector.
Depress both tabs on the connector and pull straight up. Do not pry the connector.
Note: Removal of the valve body is not necessary for the following procedure.
4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator
Assembly, Spacer Plate, and Gaskets (See:
Accumulator/Service and Repair).
5. Disconnect all the internal wiring harness electrical connectors from the electrical components
(1-6).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Page 5399
6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access
one of the TCC solenoid retaining bolts.
8. Remove the TCC solenoid bolts (68).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Page 5400
9. Remove the TCC solenoid and wiring harness (66).
Turn the wiring harness over so the wiring harness hangs down.
10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the
pressure control solenoid (377).
Note the orientation upon removal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Page 5401
12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal
wiring harness.
13. Using J 28458 , release the pass-through electrical connector from the transmission case.
1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4
tabs retaining the connector. 3. Pull the harness connector down through the transmission case.
14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the
transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following
defects:
* Damage
* Cracked connectors
* Exposed wires
* Loose pins
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Page 5402
1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the
transmission. 2. Install the pass-through electrical connector to the transmission case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid
retaining bolts. 4. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 5. Tighten the
TCC solenoid retaining bolts to 11 Nm (97 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Page 5403
Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined
(cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as
the valve body bolts are tightened and damage may occur.
6. Install the following items:
1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug
(376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid
retainer (378) 7. The solenoid retainer bolt (364)
Tighten the solenoid retainer bolt to 11 Nm (97 lb in)
7. Install the TCC PWM solenoid to the control valve body. 8. Install the TCC PWM solenoid
retainer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Page 5404
9. Connect all the internal wiring harness electrical connectors to the electrical components (1-6).
10. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See:
Accumulator/Service and Repair).
11. Connect the transmission harness 20 way connector to the transmission pass-through
connector.
Align the arrows on each half of the connector and insert straight down.
12. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Service and Repair/Removal and
Replacement).
13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) VI transmission
fluid. Refer to Transmission Fluid Check (See: Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check).
Note: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
engine control module (ECM), powertrain control module (PCM) or transmission control module
(TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP
values are learned.
15. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush
Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush
INFORMATION
Bulletin No.: 02-07-30-052G
Date: March 02, 2011
Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096
TransFlow(R)
Models:
2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010
HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle).
Important All labor operations that include removal of the transmission from the vehicle include
labor time to flush the transmission oil cooler system.
The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J
35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and
DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled
through the transmission oil cooling system. High-pressure air is automatically injected into the fluid
stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris.
In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil
cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along
with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles
and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel
has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material
that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum
evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can
be used for verification of flow test results.
Current essential cooler line adapters are used to connect the J 45096 to the automatic
transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and
light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo).
The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership
personnel with a barbed hose connector and rubber hose obtained locally. The
Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different
than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic
transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the
flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the
Vibe's/Wave's/Aveo's transmission fluid.
Notice
Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure.
The required minimum ATF oil flow rate reading is directly related to the supply oil temperature.
Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of
the ATF in the supply vessel.
Helpful Hints for Maintaining the Temperature at or above 18°C (65°F)
Important
- The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It
is recommended to store the J 45096 in an area of the dealership where the room temperature
remains at or above 18°C (65°F) when not in use.
- Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil
dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the
supply reservoir. Inserting a heater will damage the check valve and the subsequent repair
expense would be the dealer's responsibility.
- A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system
flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110
volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a
thermostat to hold a constant temperature.
Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room
where the temperature is maintained at or above 18°C (65°F).
Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J
45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is
maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the
machine on
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5409
each repair.
With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of
time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the
reservoir.
Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the
reservoir to the rays of the warm sun.
Flush / Flow Test Procedure
Important All labor operations that include removal of the transmission from the vehicle and require
the transmission oil pan or transmission side cover to be removed include labor time to flush the
transmission oil cooler system.
Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the
appropriate procedure.
Important The J 45096 can be used to flush the transmission oil cooler system on an Allison
equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission
Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure.
Machine Displays
After completion of the flush and flow test, the following information is to be recorded on the repair
order. This information is displayed on the Transmission Cooling System Service Tool, J 45096,
Transflow(R) machine when the dial is in the code position.
- Tested flow rate (displayed in Gallons Per Minute (GPM)
- Temperature (displayed is degrees Fahrenheit)
- Cycle number (a number)
- Seven digit Alpha/Numeric flow code (i.e. A10DFB2)
Warranty Information
Important All labor operations that include removal of the transmission from the vehicle include
labor time to flush the transmission oil cooler system.
Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts)
of DEXRON(R)VI transmission fluid. The amount
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5410
of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the
repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be
shown in the Parts Section of the warranty claim document.
The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and
placed in the comments section of the warranty claim. Any repair that requires the technician to
contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent
will request the seven digit flow code and add the information to the PQC case prior to providing
authorization for the warranty claim.
The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card,
entered in the warranty claim labor operation Flush Code additional field (when available) and
placed in the comments section of the warranty claim. Any repair that requires the technician to
contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent
will request the seven digit flow code and add the information to the PQC case prior to providing
authorization for the warranty claim.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5411
Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination
Information
INFORMATION
Bulletin No.: 08-07-30-035B
Date: November 01, 2010
Subject: Information on Water or Ethylene Glycol in Transmission Fluid
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission
Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin
Number 08-07-30-035A (Section 07 - Transmission/Transaxle).
Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission
components and will have a negative effect on reliability and durability of these parts. Water or
ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder
during engagement or gear changes, especially during torque converter clutch engagement.
Indications of water in the ATF may include:
- ATF blowing out of the transmission vent tube.
- ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a
strawberry milkshake.
- Visible water in the oil pan.
- A milky white substance inside the pan area.
- Spacer plate gaskets that appear to be glued to the valve body face or case.
- Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not
compressed.
- Rust on internal transmission iron/steel components.
If water in the ATF has been found and the source of the water entry has not been identified, or if a
leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in
the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of
ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be
obtained and the ATF tested to make an accurate decision on the need for radiator replacement.
This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking
and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These
test kits can be obtained from:
Nelco Company
Test kits can be ordered by phone or through the website listed above. Orders are shipped
standard delivery time but can be shipped on a next day delivery basis for an extra charge. One
test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost
of the complete test kit plus shipping charges should be divided by 10 and submitted on the
warranty claim as a net item.
The transmission should be repaired or replaced based on the normal cost comparison procedure.
Important If water or coolant is found in the transmission, the following components MUST be
replaced.
- Replace all of the rubber-type seals.
- Replace all of the composition-faced clutch plates and/or bands.
- Replace all of the nylon parts.
- Replace the torque converter.
- Thoroughly clean and rebuild the transmission, using new gaskets and oil filter.
Important The following steps must be completed when repairing or replacing.
Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number
02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096
TransFlow.
- Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5412
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair
Transmission Mount: Service and Repair
Transmission Mount Replacement (2WD)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Support the transmission with a transmission
jack. 3. Remove the 2 nuts securing the transmission mount to the transmission support. 4. Raise
the transmission off of the transmission support.
5. Remove the transmission mount bolts (4). 6. Remove the transmission mount (3). 7. Remove the
transmission mount spacer bolts (1). 8. Remove the transmission mount spacer (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > Page 5416
Installation Procedure
1. Install the transmission mount spacer (2). 2. Install the transmission mount spacer bolts (1). 3.
Install the transmission mount (3).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the bolts (4) and tighten to 55 Nm (41 lb ft).
5. Lower the transmission and install the 2 nuts securing the transmission mount to the
transmission support.
Tighten the nuts to 57 Nm (42 lb ft).
6. Remove the transmission jack. 7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
Transmission Position Switch/Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Left Side of the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5420
1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5421
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5422
Transmission Position Switch/Sensor: Diagrams
Component Connector End Views
Park/Neutral Position (PNP) Switch (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5423
Transmission Position Switch/Sensor: Service and Repair
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Service and Repair/Removal
and Replacement).
2. Remove the following parts: (89), (92), (88), (85) and (84)
3. Remove the manual shaft seal (82) with a screwdriver.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5424
1. Inspect the following items:
* Manual shaft (84) for damage or burrs
* Parking lock actuator assembly (85) for damage
* Manual shift detent lever with shaft position switch assembly (88) for damage or cracks
* Manual valve link (89) for damage
* Manual shift detent lever pin (92) discard - Do NOT reuse.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the following items:
* Manual shift detent lever with shaft position switch assembly (88)
* Parking lock actuator assembly (85)
* Manual shaft (84) (model dependent)
* NEW manual shift detent lever pin (92)
* Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft).
3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Service and Repair/Removal and
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure
Test Port, A/T > Component Information > Service and Repair
Transmission Pressure Test Port: Service and Repair
Automatic Transmission Fluid Pressure Test Hole Plug Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Remove the oil pressure test plug.
Installation Procedure
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
1. Install an oil pressure test plug and tighten to 8 Nm (71 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure
Test Port, A/T > Component Information > Service and Repair > Page 5428
2. Check the transmission fluid level, fill if necessary. Refer to Transmission Fluid Check (See:
Testing and Inspection/Component Tests and
General Diagnostics/Transmission Fluid Check).
3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams
Transmission Speed Sensor: Diagrams
Component Connector End Views
Automatic Transmission Input Shaft Speed (ISS) Sensor (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips
Valve Body: Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips
INFORMATION
Bulletin No.: 01-07-30-036H
Date: January 29, 2009
Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70)
Supercede:
This bulletin is being revised to add the 2009 model year and add details regarding spacer plates.
Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle).
Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve
Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service
Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may
also describe a condition of a second, third or fourth gear start that may have the same causes but
has not set this DTC yet. Below are some tips when diagnosing this DTC:
^ This is a performance code. This means that a mechanical malfunction exists.
^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical
connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set.
^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the
spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is
important to remove the spacer plate and inspect orifice # 29 and the immediate area for the
presence of chips/debris. Also, the transmission case passage directly above this orifice and the
valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003
and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a
bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens
can help to prevent plugging of orifice # 29 caused by small debris or chips.
^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the
2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the
valves, the bore and the valve body passages.
^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer
to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on
parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition.
Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found
to be cracked, broken or leaking.
It is important to also refer to the appropriate Service Manual or Service Information (SI) for further
possible causes of this condition.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 5439
Valve Body: Technical Service Bulletins A/T - Production Changes
INFORMATION
Bulletin No.: 08-07-30-041
Date: September 04, 2008
Subject: Information On 2009 M30 4L60E, M32 4L65E and M70 4L70E HYDRA-MATIC(R) RWD
Four Speed Automatic Transmission Controls Product Update
Models: 2009 Chevrolet Avalanche, Colorado, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer
SS 2009 GMC Canyon, Envoy, Envoy Denali, Savana, Sierra, Yukon 2009 Saab 9-7X Models
Equipped with HYDRA-MATIC(R) 4L60E, 4L65E, 4L70E Four Speed RWD Automatic
Transmission (RPOs M30, M32, M70)
For the 2009 model year, there are several controls changes to the 4L60E, 4L65E and 4L70E.
The valve body casting has been changed and will not back service due to the removal of the
components shown above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 5440
1. A new Internal Mode Switch (IMS) has been added (2). The PSM has been deleted.
^ Do not reuse the roll pin that retains the IMS (2) to the manual shaft (3).
^ Do not remove the "C" clip from the IMS (2). This will damage the part.
2. The manual shaft (3) has been redesigned to accommodate the IMS (2).
3. The actuator rod (1) is a new design and will back service. It has a flat on the rod to
accommodate the IMS (2).
The wiring harness has been changed and now has the temperature sensor (2) in the harness with
a gray connector. Both the 20-way connector (1) and the 6-pin connector for the IMS are now blue
in color (3).
The new DTCs shown above have been added for the IMS.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 5441
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 5442
Valve Body: Service and Repair
Control Valve Body Replacement
Removal Procedure
1. Remove the fluid level indicator. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle
(See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the oil pan, gasket, and filter.
Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal
and
Replacement).
4. Disconnect all the internal wiring harness electrical connectors from the electrical connectors
(1-6) components.
5. Remove the torque converter clutch (TCC) pulse width modulation (PWM) solenoid retainer (2)
with a small screwdriver. Rotate the solenoid (1)
in the bore, if necessary, until the flat part of the retainer (2) is visible.
6. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 5443
7. Remove the TCC solenoid retaining bolts (68).
8. Remove the TCC solenoid (with O-ring seal) and wiring harness (66) from the control valve
body. 9. Reposition the harness to the side of the transmission case.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 5444
10. Remove the manual detent spring bolt (64) and the spring assembly (63).
11. Remove all valve body bolts (59, 62, 120).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 5445
12. Carefully begin to lower the control valve body down from the transmission case while
simultaneously disconnecting the manual valve link.
Installation Procedure
1. Install the checkballs (1-7) in the valve body.
2. Install the control valve body to the transmission case while simultaneously connecting the
manual valve link to the manual valve. 3. Verify that the manual valve link is installed properly to
the inside detent lever and the manual valve.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 5446
4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place.
5. Install the 12 valve body bolts (62), 2 bolts (59) and 3 bolts (120) that are shown only. 6. Finger
tighten the bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 5447
7. Install the transmission wiring harness on the valve body.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
8. Install the TCC solenoid valve and bolts (68).
Tighten the bolts to 814 Nm (610 lb ft).
Caution: Do not over-tighten the bolts. Over-tightening the bolts will distort the valve bores. Begin
tightening from the center of the valve body tighten the bolts in a outward direction.
9. Inspect the ensure all of the valve body bolts are in the correct location. Each bolt number refers
to a specific size, as indicated in the following
list:
* 59 M6 x 1.0 x 35.0 (Qty: 2)
* 62 M6 x 1.0 x 47.5 (Qty: 12)
* 120 M6 x 1.0 x 54.4 (Qty: 3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 5448
10. Tighten the bolts from the center of the valve body working your way out in a spiral pattern to
the outside edge.
Tighten the bolts to 814 Nm (610 lb ft).
11. Install the TCC PWM solenoid valve (396) and the solenoid retainer (395).
12. Snap the wiring harness in place on the valve body bolts. Ensure the harness loom tab is
located under the transmission fluid pressure (TFP)
switch.
13. Install the wiring connectors to the electrical components (1-6) as indicated in the following list:
1. The manual shift detent lever with shaft position switch assembly 2. The 1-2 shift solenoid 3. The
2-3 shift solenoid 4. The pressure control solenoid (PCS) 5. The TCC PWM solenoid 6. The input
speed sensor (ISS)
14. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Service and Repair/Removal and
Replacement).
15. Lower the vehicle. 16. Fill the transmission to the proper level with DEXRON(R) VI transmission
fluid. Refer to Transmission Fluid Check (See: Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check).
Note: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
engine control module (ECM), powertrain control module (PCM) or transmission control module
(TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP
values are learned.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 5449
17. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information >
Service and Repair
Clutch Disc: Service and Repair
Clutch Assembly Replacement
Special Tools
J 36660-A Torque Angle Meter
Removal Procedure
1. Remove the transmission. Refer to Transmission Replacement (4WD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and
Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission
Replacement).
2. Remove the clutch pressure plate bolts (1).
Discard the bolts.
3. Remove the clutch pressure plate (2) and driven disc (3) from the dowel pins (4) on the flywheel
(5).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information >
Service and Repair > Page 5454
1. Install the clutch pressure plate (2) and driven plate (3) to the dowel pins (4) on the flywheel (5).
2. Install the clutch pressure plate bolts (1) finger tight. 3. Use the Snap-On A145 Clutch Aligner
Set, or equivalent, to align the clutch driven plate (3) to the clutch pilot bearing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Tighten the NEW clutch pressure plate bolts in the sequence shown.
1. Tighten the clutch pressure plate bolts in sequence to 20 Nm (15 lb ft). 2. Use the J 36660-A in
order to tighten the clutch pressure plate bolts in sequence an additional 45 degrees.
5. Install the transmission. Refer to Transmission Replacement (4WD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and
Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid >
Component Information > Specifications
Clutch Fluid: Specifications
HYDRAULIC CLUTCH FLUID
GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master
Cylinder > Component Information > Service and Repair
Clutch Master Cylinder: Service and Repair
Clutch Master Cylinder Replacement
Tools Required
J 42371 Hydraulic Clutch Line Separator
Removal Procedure
Important: A new retainer (3) is required after removal.
1. Complete the following in order to disengage the retainer (3) from the clutch pedal pin.
1. Insert a flat bladed tool (4) between the clutch master cylinder push rod (1) and the clutch pedal
(2). 2. Pry the clutch master cylinder push rod (1) away from the clutch pedal assembly (2).
Discard the retainer (3).
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master
Cylinder > Component Information > Service and Repair > Page 5462
3. Using the J 42371 , push back the white plastic sleeve on the quick connect in order to separate
the hydraulic clutch hose from the clutch actuator
quick connect. It is not necessary to plug the lower hose end or slave cylinder fitting as they are
equipped with check valves, only minimal fluid loss may be experienced.
4. Disconnect the clutch hydraulic hose retainer from the inner fender. 5. Lower the vehicle.
6. Rotate the clutch master cylinder clockwise 1/8 turn.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master
Cylinder > Component Information > Service and Repair > Page 5463
7. Remove the clutch master cylinder with hydraulic hose from the cowl.
Installation Procedure
1. Route the clutch hydraulic hose with master cylinder under the brake booster.
2. With the clutch fluid reservoir cap at the 1:30 position. Insert the clutch master cylinder into the
cowl.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master
Cylinder > Component Information > Service and Repair > Page 5464
3. Rotate the clutch master cylinder counter clockwise 1/8 turn until fully seated.
The clutch fluid reservoir cap will be vertical at the 12:00 position when the clutch master cylinder is
properly installed.
4. Raise the vehicle.
Important: Ensure the clutch hydraulic hose does not come in contact with any sharp or potentially
hot surfaces.
5. Push the clutch hydraulic hose quick connect fitting (2) into the clutch slave cylinder, until a
"click" is heard. 6. Tug gently on the clutch hydraulic hose to ensure proper retention into the clutch
slave cylinder. 7. Connect the clutch hydraulic hose retainer to the inner fender. 8. Lower the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master
Cylinder > Component Information > Service and Repair > Page 5465
9. Insert a new retainer (3) into the clutch master cylinder push rod (1).
10. Push the clutch master cylinder push rod (1) onto the clutch pedal pin to secure. 11. Adjust the
clutch release switch. Refer to Clutch Pedal Cruise Control Release Switch Adjustment (See:
Cruise Control/Clutch
Switch/Adjustments).
12. Adjust the clutch pedal position switch. Refer to Clutch Pedal Position Switch Replacement
(See: Clutch Pedal Position Sensor / Switch/Service
and Repair).
13. Bleed the clutch hydraulic system, only if necessary. Refer to Hydraulic Clutch Bleeding (See:
Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave
Cylinder > Component Information > Service and Repair
Clutch Slave Cylinder: Service and Repair
Clutch Actuator Cylinder Replacement
Removal Procedure
1. Remove the transmission. Refer to Transmission Replacement (4WD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and
Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission
Replacement).
2. Remove the 2 clutch actuator cylinder bolts (3). 3. Remove the clutch actuator cylinder (1) from
the input shaft bearing retainer (2).
Installation Procedure
1. Position the clutch actuator cylinder (1) to the input shaft bearing retainer (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave
Cylinder > Component Information > Service and Repair > Page 5469
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the 2 clutch actuator cylinder bolts (3).
Tighten the clutch actuator cylinder bolts to 8 Nm (71 lb in).
3. Install the transmission. Refer to Transmission Replacement (4WD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and
Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component
Information > Service and Repair
Clutch Pedal Assembly: Service and Repair
Clutch Pedal Replacement
Removal Procedure
1. Disconnect the electrical connectors (2, 4) from the following components:
* The clutch pedal position switch (1)
* The cruise control release switch (3)
Note: A new retainer (3) is required after removal.
2. Complete the following in order to disengage the retainer (3) from the clutch pedal pin.
1. Insert a flat-bladed tool (4) between the clutch master cylinder push rod (1) and the clutch pedal
(2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component
Information > Service and Repair > Page 5473
2. Pry the clutch master cylinder push rod (1) away from the clutch pedal assembly (2).
Discard the retainer (3).
3. Remove the 4 nuts securing the clutch pedal assembly to the cowl. 4. Remove the clutch pedal
assembly from the vehicle.
Installation Procedure
1. Position the clutch pedal assembly over the studs.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the clutch pedal assembly nuts and tighten to 20 Nm (15 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component
Information > Service and Repair > Page 5474
3. Insert a new retainer (3) into the clutch master cylinder push rod (1). 4. Push the clutch master
cylinder push rod (1) onto the clutch pedal pin to secure.
5. Connect the electrical connectors (2, 4) to the following components:
* The clutch pedal position switch (1)
* The cruise control release switch (3)
6. Adjust the clutch release switch. Refer to Clutch Pedal Cruise Control Release Switch
Adjustment (See: Cruise Control/Clutch
Switch/Adjustments).
7. Adjust the clutch pedal position switch. Refer to Clutch Pedal Position Switch Replacement (See:
Clutch Pedal Position Sensor / Switch/Service
and Repair).
8. Check for proper clutch pedal movement and operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch >
Component Information > Diagrams
Clutch Pedal Position Sensor / Switch: Diagrams
Component Connector End Views
Clutch Pedal Position (CPP) Sensor (MA5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch >
Component Information > Diagrams > Page 5478
Clutch Pedal Position Sensor / Switch: Service and Repair
Clutch Pedal Position Switch Replacement
Removal Procedure
1. Disconnect the electrical connector (2) from the clutch pedal position switch (1).
2. Push the clutch pedal position switch retaining plate locking tabs (2) inward toward each other to
release. 3. Remove the clutch pedal position switch (3) from the clutch pedal assembly (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch >
Component Information > Diagrams > Page 5479
1. Slide the clutch pedal position switch (3) with retaining plate (2) into the clutch pedal bracket (1),
until the locking tabs (2) are fully engaged.
2. Connect the electrical connector (2) to the clutch pedal position switch (1). 3. Complete the
following in order to adjust the clutch pedal position switch (1).
1. Push the switch fully into the bracket, allowing the switch to ratchet in the retaining plate. 2.
Depress the clutch pedal all the way to the floor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information >
Locations
Clutch Switch: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information >
Locations > Page 5483
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information >
Locations > Page 5484
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information >
Locations > Page 5485
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information >
Locations > Page 5486
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component
Information > Service and Repair
Clutch Release Bearing: Service and Repair
Clutch Release Bearing Replacement
Removal Procedure
1. Remove the transmission. Refer to Transmission Replacement (4WD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and
Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission
Replacement).
2. Pull the clutch actuator cylinder release bearing (2) from the clutch actuator cylinder dust cover
(1).
Installation Procedure
Important: Do not allow the release bearing to become damaged, replace if dropped or damaged.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component
Information > Service and Repair > Page 5490
1. Install the clutch actuator cylinder release bearing (2) over the clutch actuator cylinder dust cover
(1). 2. Install the transmission. Refer to Transmission Replacement (4WD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and
Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information >
Service and Repair
Pilot Bearing: Service and Repair
Clutch Pilot Bearing Replacement
Special Tools
* J 43276 Clutch Pilot Bearing Remover
* J 45949 Pilot Bearing and Flywheel Locator Installer
Removal Procedure
Caution: When using the J 43276 Clutch Pilot Bearing Remover, always secure the J 43276-1
Clutch Pilot Bearing Remover tool body using a wrench. Do not allow the J 43276-1 tool body to
rotate. Failing to do so causes damage to the J 43276-1 tool body.
1. Remove the flywheel. Refer to Engine Flywheel Replacement (with Automatic Transmission)
()Engine Flywheel Replacement (with Manual
Transmission) () for the 2.9L engine or Engine Flywheel Replacement (with Manual Transmission)
()Engine Flywheel Replacement (with Automatic Transmission) () for the 3.7L engine.
2. Using the J 43276 perform the following in order to remove the clutch pilot bearing:
1. Install the J 43276-1 into the clutch pilot bearing. 2. Using a wrench, secure the J 43276-1. 3.
Insert the J 43276-2 into the J 43276-1. 4. Rotate the J 43276-2 clockwise into the J 43276-1 until
the clutch pilot bearing is completely removed from the crankshaft. 5. Rotate the J 43276-2
counterclockwise to remove the J 43276-2 from the J 43276-1. 6. Remove the J 43276-1 from the
tool body.
3. Discard the old clutch pilot bearing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information >
Service and Repair > Page 5494
1. Install the J 45949 (3) into the clutch pilot bearing (1). 2. Install the clutch pilot bearing (1) into
the crankshaft (2).
The J 45949 (3) will install the pilot bearing (1) to the proper depth of 11.6 mm (0.457 in) (a).
3. Remove the J 45949 (3). 4. Install the flywheel. Refer to Engine Flywheel Replacement (with
Automatic Transmission) ()Engine Flywheel Replacement (with Manual
Transmission) () for the 2.9L engine or Engine Flywheel Replacement (with Manual Transmission)
()Engine Flywheel Replacement (with Automatic Transmission) () for the 3.7L engine.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information >
Specifications
Pressure Plate: Specifications
PRESSURE PLATE
clutch pressure plate bolts in sequence to...........................................................................................
.............................................................20 Nm (15 lb ft) clutch pressure plate bolts in sequence an a
dditional...............................................................................................................................................
45 degrees
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information >
Specifications > Page 5498
Pressure Plate: Service and Repair
Clutch Assembly Replacement
Special Tools
J 36660-A Torque Angle Meter
Removal Procedure
1. Remove the transmission. Refer to Transmission Replacement (4WD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and
Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission
Replacement).
2. Remove the clutch pressure plate bolts (1).
Discard the bolts.
3. Remove the clutch pressure plate (2) and driven disc (3) from the dowel pins (4) on the flywheel
(5).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information >
Specifications > Page 5499
1. Install the clutch pressure plate (2) and driven plate (3) to the dowel pins (4) on the flywheel (5).
2. Install the clutch pressure plate bolts (1) finger tight. 3. Use the Snap-On A145 Clutch Aligner
Set, or equivalent, to align the clutch driven plate (3) to the clutch pilot bearing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Tighten the NEW clutch pressure plate bolts in the sequence shown.
1. Tighten the clutch pressure plate bolts in sequence to 20 Nm (15 lb ft). 2. Use the J 36660-A in
order to tighten the clutch pressure plate bolts in sequence an additional 45 degrees.
5. Install the transmission. Refer to Transmission Replacement (4WD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and
Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual
Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information
Continuously Variable Transmission/Transaxle: Technical Service Bulletins A/T Controls Snapshot Data Upload Information
INFORMATION
Bulletin No.: 07-07-30-010B
Date: June 19, 2009
Subject: Procedure to Take Snapshot Data with a Tech 2(R) and Upload Data to a Computer Using
TIS Software
Models:
2004-2010 Passenger Cars and Light Duty Truck (Including Saturn; excluding Astra models)
2004-2010 HUMMER H2, H3 2004-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the Sending a Snapshot to GM TAC section
and add the 2010 model year. Please discard Corporate Bulletin Number 07-07-30-010A (Section
07 - Transmission/Transaxle).
Important Global Diagnostic System (GDS) will take the place of the Tech 2(R) on certain vehicles
when communicating and diagnosing vehicle on-board electrical systems. This new diagnostic tool
platform and software will be required for use with all GM Global Architecture (Global A) vehicles
beginning with the 2010 Chevrolet Camaro, followed later by the Buick Allure/LaCrosse, Chevrolet
Equinox, Cadillac SRX and the GMC Terrain. These vehicles will no longer permit Tech 2(R)
communication for diagnostic purposes. For further information, refer to Corporate Bulletin Number
09-00-89-019 (Introduction of New Global Diagnostic System (GDS)).
This procedure is intended to show the user how to take snapshot data with a Tech 2(R) and
upload it to a computer. The procedure is written for an automatic transmission data snapshot on a
Saturn AURA, but is similar for all applications. This procedure is written with the assumption the
user has a basic understanding of how to use a Tech 2(R) already.
Capturing a Snapshot of the Vehicle Data Stream
1. Connect the Tech 2(R) to the vehicle Data Link Connector (DLC) as shown above. Use a CANdi
module as required. 2. Power up the Tech 2(R) and press the ENTER key at the start-up screen.
3. From the Main Menu select F0: Diagnostics. 4. Enter all vehicle information as requested on the
scan tool's display. Bolded selections are vehicle specific.
- Select "2007"
- Select "Passenger Car (F0)"
- Select "Saturn"
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 5504
- Select "Z"
- Select "Aura"
- Select "Powertrain"
- Select "3.6L LY7"
- Select "Transmission"
- Select "Transmission Data"
5. From the application menu, select F3: Snapshot.
- Choose trigger type and trigger point, as described above.
- It is preferred to trigger on "Any Code" (F1)
- If multiple codes are setting, select "Single Code" and enter the code you are trying to capture on
the next screen.
- Select "Center (F5)" for the trigger point. This allows the requester/viewer of the data to see the
events before and after the code sets.
6. Press the Record Snapshot soft key. The Tech 2(R) screen will display the parameters it is going
to record for live viewing.
- When the fault occurs, the Tech 2(R) will automatically start recording if the preferred settings (F1
and F5) are selected.
- If manual trigger is selected during the setup procedure, you will have to hit the "Trigger" soft key
to actually record data. Otherwise, it will automatically start recording when a DTC is set.
- Allow the Tech 2(R) to record the data. Please note that a Tech 2(R) can record a maximum of 1
minute of data (30 seconds before and 30 seconds after the trigger point if center trigger is
selected).
Important The Tech(R)2 can only record two snapshots prior to uploading to a computer. If a third
snapshot is requested, the first snapshot will be overwritten.
7. When the snap shot data has been recorded, exit to the Main Menu, then power down and
disconnect the Tech 2(R) from the vehicle.
Uploading and Sending a Snapshot via TIS2WEB
Figure 8
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 5505
Figure 9
1. Once TIS2WEB is launched and you're at the main screen, select Snapshot, indicated with a
arrow in Figure 8. 2. Select the Upload from Handheld button to launch the device selection screen
just like the TIS 2000 procedure described above.
Figure 10
3. Select the top button, "Upload from Handheld" which will launch the screen displayed in Figure
10. Make sure the Tech 2(R) is connected to the
computer and plugged in. Select Tech 2(R) under Device and select OK. The screen of your Tech
2(R) should start blinking and a line will start scrolling across the screen indicating it is
communicating with your computer.
Figure 11
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 5506
4. Once communication is established and you select the file you want to upload, you will see a
screen similar to below. You can email the file
directly from TIS2WEB by going to the Snapshot drop down menu and selecting "Send to e-mail"
as shown in Figure 11.
Figure 12
5. After selecting Send to e-mail, a dialog box like the one shown in Figure 12 will be displayed. Fill
in the information as requested and then click
send. Include the VIN in the subject line.
6. After all the information is entered, hit the send button. After sending the file, you will receive a
confirmation box letting you know the e-mail was
sent successfully.
7. It is recommended to now save the file to your computer using the same procedure as if you
were using TIS 2000 in case your recipient doesn't
receive your email with the snapshot data.
Important Sending the file via e-mail through TIS2WEB does NOT save the file locally and there is
no way to access your sent mail in TIS2WEB like a regular e-mail program.
Sending a Snapshot to GM TAC
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 5507
During your call with GM TAC on a current case, you may be advised to send a copy of the Tech
2(R) or VDR Snapshot Data to the TAC e-mail box.
U.S. Dealers - send to e-mail box
[email protected]
Canadian Dealers - send to e-mail box
[email protected]
Please complete the following:
- Be sure to review the procedures listed above for uploading and sending a Snapshot via
TIS2WEB.
- If you are using a VDR to capture Snapshot Data, information can be accessed in the Techlink
Website in the articles (December 2002, December 2003, July 2004 and January 2006).
- Please be sure to identify the snapshot by placing the TAC Case Number, the last eight digits of
the VIN and the type of data (i.e. engine or transmission) in the subject line of your e-mail. The
email Subject Line MUST contain the TAC case number and last 8 digits of the VIN or their email
can not be processed and will be deleted.
Please send only REQUESTED Snapshot Data to the TAC e-mail box.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 5508
Continuously Variable Transmission/Transaxle: Technical Service Bulletins Vehicle - Engine
Crankcase and Subsystems Flushing Info.
INFORMATION
Bulletin No.: 04-06-01-029E
Date: April 29, 2010
Subject: Unnecessary Flushing Services, Additive Recommendations and Proper Utilization of GM
Simplified Maintenance Schedule to Enhance Customer Service Experience
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and add information about the
proper transmission flush procedure. Please discard Corporate Bulletin Number 04-06-01-029D
(Section 06 - Engine/Propulsion System).
An Overview of Proper Vehicle Service
General Motors is aware that some companies are marketing tools and equipment to support a
subsystem flushing procedures. These dedicated machines are in addition to many engine oil,
cooling system, fuel system, A/C, transmission flush and steering system additives available to the
consumer. GM Vehicles under normal usage do not require any additional procedures or additives
beyond what is advised under the former Vehicle Maintenance Schedules or the current Simplified
Maintenance Schedules. Do not confuse machines available from Kent-Moore/SPX that are
designed to aid and accelerate the process of fluid changing with these flushing machines.
Engine Crankcase Flushing
General Motors Corporation does not endorse or recommend engine crankcase flushing for any of
its gasoline engines. Analysis of some of the aftermarket materials used for crankcase flushing
indicate incompatibility with GM engine components and the potential for damage to some engine
seals and bearings. Damage to engine components resulting from crankcase flushing IS NOT
COVERED under the terms of the New Vehicle Warranty.
GM Authorized Service Information: Detailed, Descriptive, and Complete
If a specific model vehicle or powertrain need is identified, GM will issue an Authorized Service
Document containing a procedure and, if required, provide, make available, or require the specific
use of a machine, tool or chemical to accomplish proper vehicle servicing. An example of this is
fuel injector cleaning. Due to variation in fuel quality in different areas of the country, GM has
recognized the need for fuel injector cleaning methods on some engines, though under normal
circumstances, this service is not part of the maintenance requirements.
GM has published several gasoline fuel injector cleaning bulletins that fully outline the methods to
be used in conjunction with GM Part Numbered solutions to accomplish proper and safe cleaning
of the fuel injectors with preventative maintenance suggestions to maintain optimum performance.
You may refer to Corporate Bulletin Numbers 03-06-04-030 and 04-06-04-051 for additional
information on this subject.
Subsystem Flushing
Flushing of A/C lines, radiators, transmission coolers, and power steering systems are recognized
practices to be performed after catastrophic failures or extreme corrosion when encountered in
radiators. For acceptable A/C flushing concerns, refer to Corporate Bulletin Number 01-01-38-006.
This practice is NOT required or recommended for normal service operations.
The use of external transmission fluid exchange or flush machines is NOT recommended for the
automatic or manual transmission. Use of external machines to replace the fluid may affect the
operation or durability of the transmission. Transmission fluid should only be replaced by draining
and refilling following directions in SI. Refer to Automatic/Manual Transmission Fluid and Filter
Replacement.
Approved Transmission Flushing Tool (Transmission Cooler Only)
The Automatic Transmission Oil Cooler Flush and Flow Test Tool is recommended for GM
vehicles. Refer to Transmission Fluid Cooler Flushing and Flow Test in SI using the J 45096.
Service Is Important to You and Your Customer
General Motors takes great pride in offering our dealerships and customers high quality vehicles
that require extremely low maintenance over the life of the vehicle. This low cost of ownership
builds repeat sales and offers our customers measurable economy of operation against competing
vehicles.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 5509
Providing responsible services at the proper intervals will greatly aid your dealership with repeat
business, and additional services when required. Most customers appreciate and gain trust in the
dealership that informs and offers them just what they need for continued trouble-free operation.
Examine your service department's practices and verify that all Service Consultants and
Technicians focus on customer satisfaction, vehicle inspections, and other products at time of
service. Use this opportunity to upgrade the services you provide to your customers. Here are a
few suggestions:
- Take the time required to align your dealership service practices with the new GM Simplified
Maintenance Schedule. Use the new vehicle Owner's Manual Maintenance I and II schedules to
create a "mirror image" in your advertising and dealer service pricing that is easily understandable
to your customer. Taking advantage of this new service strategy may greatly increase your
dealership service sales and customer retention while decreasing the frequency of visits and
inconvenience to your customer.
- Review your program to ensure that all vehicles coming in are evaluated for safety and wear
items. Examine all vehicles for tire condition, signs of misalignment, brake wear, exterior lamp
functionality, exhaust condition, A/C cooling performance, SRS or Air Bag MIL, along with Service
Engine Soon or Check Engine indicators. If the Service Engine Soon or Check Engine MIL is
illuminated, it is vital that you inform the customer of the concerns with ignoring the indicator and
what the required repair would cost. In addition to the possibility of increased emissions and
driveability concerns, many customers are unaware that lower gas mileage may also result, with
additional cost to the customer.
- Be complete in your service recommendations. Some sales opportunities are not being fully
pursued nationally. Focus on overlooked but required maintenance that has real benefits to the
customer. Many vehicles are equipped with cabin air filters. If these filters are used beyond
replacement time, they may impede airflow decreasing A/C and heating performance. Make sure
these filters are part of your recommended service. Note that some of our vehicles may not have
been factory equipped but will accept the filters as an accessory.
- Express the value in maintaining the finish quality of the customer's vehicle at the Maintenance I
and II visits. More fully utilize the vehicle prep personnel you already have in place. In today's
world, many people simply ignore the finish of their vehicle, at best infrequently using an automatic
car wash for exterior cleaning. Offer vehicle detailing services in stages from just a wash and wax
to a complete interior cleaning. When paired with the Simplified Maintenance visit, this will increase
customer satisfaction. On return, the customer gets a visibly improved vehicle that will be a source
of pride of ownership along with a vehicle that is now fully maintained. Also, reinforce the improved
resale value of a completely maintained vehicle.
- For customers who clean and maintain the appearance of their vehicles themselves encourage
the use of GM Vehicle Care products. Many customers may have never used GM Car Wash/Wax
Concentrate, GM Cleaner Wax or a longtime product, GM Glass Cleaner, which is a favorite of
many customers who try it just once. If your dealership give samples of these products with new
car purchases, customers may already be sold on the product but not willing to make a special trip
to the dealership. Capitalize on sales at this time. Stock shelves right at the Service counter with
these products and consider instituting compensation programs for Service Consultants who
suggest these products. Many consumers faced with an intimidating wall full of car care products
sold at local auto parts stores may find it comforting to purchase a fully tested product sold by GM
that they know will not harm the finish of their vehicle. We suggest these competitively priced basic
vehicle care products to emphasize:
In USA:
- #12378401 GM Vehicle Care Wash/Wax Concentrate 16 fl. oz. (0.473L)
- #89021822 GM Vehicle Care Glass Cleaner Aerosol 18 oz. (510 g)
- #12377966 GM Vehicle Care Cleaner Wax 16 fl. oz. (0.473L)
- #1052929 GM Vehicle Care Chrome and Wire Wheel Cleaner 16 fl. oz. (0.473L)
- #88861431 GM Vehicle Care Odor Eliminator 24 fl. oz. (0.710L)
In Canada:
- #10953203 GM Vehicle Care Wash & Wax Concentrate 473 mL
- #992727 GM Glass Cleaner Aerosol 500 g
- #10952905 GM Vehicle Care Liquid Cleaner/Wax 473 mL
- #10953013 GM Vehicle Care Chrome Cleaner and Polish 454 mL
- #10953202 GM Vehicle Care Wheel Brite 473 mL
- #88901678 GM Vehicle Care Odor Eliminator 473 mL
- Display signboards with the installed price for popular GM Accessories such as running boards
and Tonneau Covers. Customers may not think to ask about these desirable items at the time of a
service visit.
- Finally, take advantage of the GM Goodwrench initiatives (Tire Program, Goodwrench Credit
Card, etc. / Dealer Marketing Association (DMA) Promotions in Canada) to provide the customer
with more reasons to identify your dealership as the best place to go for parts and service.
Remember to utilize ALL of the service aspects you possess in your dealership to satisfy and
provide value to your customer. Many businesses exist profitably as an oil change location, a
vehicle repair facility, or a detailing shop alone. You already have the capabilities of all three and
provide these services with the inherent trust of your customer, under the GM Mark of Excellence.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential
> Actuator, Differential Lock > Component Information > Service and Repair
Actuator: Service and Repair
Electric Motor Actuator Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine protection shield (EPS).
Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service
and
Repair).
3. Remove the electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential
> Actuator, Differential Lock > Component Information > Service and Repair > Page 5515
4. Remove the electric motor actuator.
Installation Procedure
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
Note: Apply TEFLON(TM) tape to the threads of the electric actuator motor before installation.
1. Install the electric motor actuator and tighten to 22 Nm (16 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential
> Actuator, Differential Lock > Component Information > Service and Repair > Page 5516
2. Install the electrical connector.
3. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid Plate/Service and Repair). 4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings
> Component Information > Service and Repair > Differential Side Bearings Replacement (8.0 Inch Axle)
Carrier Bearings: Service and Repair Differential Side Bearings Replacement (8.0 Inch Axle)
Differential Side Bearings Replacement (8.0 Inch Axle)
Tools Required
* J 8092 Universal Driver Handle- 3/4 in - 10
* J 21784 Side Bearing Installer
* J 22888-D Side Bearing Puller Kit
* J 45231 Differential Side Bearing Installer
Removal Procedure
1. Remove the differential. Refer to Differential Replacement (See: Service and Repair/Removal
and Replacement/Rear Drive Axle/Differential
Replacement).
2. Remove the differential side bearings by performing the following steps:
1. Install the differential assembly in a vise. 2. Install the J 22888-20A (2) and the J 8107-2 (1), as
shown. 3. Remove the differential side bearings using the J 22888-20A .
3. Remove the differential assembly from the vise.
Installation Procedure
1. Install the differential side bearings by doing the following:
1. In order to protect the differential case, install the J 8107-2 in the case on the side opposite the
bearing installation. 2. Install the J 45231 (2), and the J 8092 (1) onto the differential case bearing
as shown. 3. Drive the bearing onto the case using the J 45231 (2) and the J 8092 (1).
2. Install the differential. Refer to Differential Replacement (See: Service and Repair/Removal and
Replacement/Rear Drive Axle/Differential
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings
> Component Information > Service and Repair > Differential Side Bearings Replacement (8.0 Inch Axle) > Page 5522
Carrier Bearings: Service and Repair Differential Side Bearings Replacement (8.6 Inch Axle)
Differential Side Bearings Replacement (8.6 Inch Axle)
Tools Required
* J 22912-B Split Plate Bearing Puller
* J 8092 Universal Driver Handle - 3/4 in - 10
* J 21784 Side Bearing Installer
* J 22888-D Side Bearing Remover Kit
* J 29710 Differential Side Bearing Installer
* J 44420 Differential Bearing and Hub Seal Installer
Removal Procedure
1. Remove the differential assembly. Refer to Differential Replacement (See: Service and
Repair/Removal and Replacement/Rear Drive
Axle/Differential Replacement).
2. Remove the differential side bearings by doing the following:
1. Install the differential assembly into a vise. 2. Install the J 22888-20A (2) and the J 8107-4 , over
the differential case side bearing bore. 3. Remove the differential side bearings using the J
22888-20A .
Installation Procedure
1. Install the differential side bearings by doing the following:
1. In order to protect the differential case, install the J 8107-4 in the case on the side opposite the
bearing installation. 2. Install the J 21784 (2), and the J 8092 (1) onto the differential case bearing
as shown. 3. Drive the bearing onto the case using the J 21784 or the J 29710 and the J 8092 .
2. Install the differential assembly. Refer to Differential Replacement (See: Service and
Repair/Removal and Replacement/Rear Drive
Axle/Differential Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Service and Repair
Differential Cover: Service and Repair
Rear Axle Housing Cover and Gasket Replacement
Removal Procedure
Caution: Refer to Differential Housing Cover and Gasket Removal Caution (See: Service
Precautions).
Note: The gasket and rear cover are reusable. Replace them only if they are damaged.
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Remove the bolt for the rear brake pipe retainer.
3. Remove the bolt for the mounting bracket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Service and Repair > Page 5526
4. Remove the mounting brackets from the rear axle cover. 5. Position a suitable drain pan under
the axle. 6. Remove the rear cover mounting bolts. 7. Remove the rear cover and gasket from the
differential housing. 8. Drain the rear axle.
Installation Procedure
1. Clean the contact area for the rear cover and gasket and the differential housing. 2. Install the
retainer and mounting bracket for the rear brake pipe.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Service and Repair > Page 5527
3. Install the mounting bolt for the mounting bracket. 4. Finger tighten the bolt for the mounting
bracket. 5. Install the axle housing cover and gasket.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the mounting bolts and tighten to 30 Nm (22 lb ft).
7. Install the retaining bolt for the brake pipe retainer and tighten to 20 Nm (14 lb ft). 8. Fill the rear
axle with fluid. Refer to Rear Axle Lubricant Level Inspection (8.0 Inch Axle) (See: Fluid Differential/Service and
Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.0 Inch Axle))Rear Axle
Lubricant Level Inspection (8.6 Inch Axle) (See: Fluid - Differential/Service and
Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6 Inch Axle)).
9. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator,
Differential Lock > Component Information > Service and Repair
Actuator: Service and Repair
Electric Motor Actuator Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine protection shield (EPS).
Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service
and
Repair).
3. Remove the electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator,
Differential Lock > Component Information > Service and Repair > Page 5532
4. Remove the electric motor actuator.
Installation Procedure
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
Note: Apply TEFLON(TM) tape to the threads of the electric actuator motor before installation.
1. Install the electric motor actuator and tighten to 22 Nm (16 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator,
Differential Lock > Component Information > Service and Repair > Page 5533
2. Install the electrical connector.
3. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid Plate/Service and Repair). 4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component
Information > Service and Repair
Differential Mount: Service and Repair
Differential Carrier Assembly Bushing and Bracket Replacement
Removal Procedure
Note: The bushing for the mounting bracket are not serviced separately. They are serviced with the
mounting bracket.
1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Drive Axles,
Bearings and Joints/Axle Shaft Assembly/Service and
Repair).
2. Support the front drive axle assembly.
3. Remove the mounting bracket to frame bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component
Information > Service and Repair > Page 5537
4. Remove the bolts mounting the bracket to the disconnect housing.
5. Remove the mounting bracket.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component
Information > Service and Repair > Page 5538
1. Position the mounting bracket to the frame.
Note: In the following service procedure, DO NOT completely tighten the bolts mounting the
bracket to the frame. Leave the bolts loose to allow for bracket alignment to the intermediate shaft
housing.
2. Install the mounting bracket bolts to the frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component
Information > Service and Repair > Page 5539
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the mounting bracket bolts to the intermediate shaft housing and tighten the bolts to 152
Nm (112 lb ft). 4. Tighten the mounting bracket bolts to 152 Nm (112 lb ft). 5. Remove the support
from the front drive axle assembly.
6. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Drive Axles,
Bearings and Joints/Axle Shaft Assembly/Service and
Repair).
7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
DIFFERENTIAL FLUID Front Axle ......................................................................................................
......................................................................................... 1.5 liters (3.2 pints) Rear Axle 8.0 inch ......
..............................................................................................................................................................
............................... 1.7 liters (3.6 pints) 8.6 inch ................................................................................
................................................................................................................. 2.03 liters (4.3 pints)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications > Page 5544
Fluid - Differential: Fluid Type Specifications
FRONT AND REAR AXLE SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in
Canada 89021678) meeting GM Specification 9986115.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Service and Repair > Procedures
Fluid - Differential: Procedures
Front Drive Axle
Front Axle Lubricant Level Inspection
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Ensure the vehicle is level. 3. Inspect the front axle for leaks. Repair
as necessary. 4. Remove the engine protection shield (EPS), if equipped. Refer to Engine
Protection Shield Replacement (See: Body and Frame/Frame/Skid
Plate/Service and Repair).
5. Clean the area around the front axle fill plug. 6. Remove the front axle fill plug and the washer. 7.
Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L".
Note: Ensure that the pipe cleaner is resting on the bottom threads of the fill hole.
8. Insert the pipe cleaner into the fill plug opening with the stem "L" is facing down. 9. Remove the
pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level.
The oil level should be between 0-8 mm (0-0.4 in) below the fill plug opening.
10. If the level is low, add fluid until the level is within the proper fluid level specification. Use the
proper fluid. Refer to Fluid and Lubricant
Recommendations (See: Maintenance/Service Intervals).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
11. Install the fill plug and the washer and tighten the plug to 32 Nm (24 lb ft). 12. Install the EPS, if
equipped. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid
Plate/Service and Repair). 13. Lower the vehicle.
Rear Axle Lubricant Level Inspection (8.0 Inch Axle)
Rear Axle Lubricant Level Inspection (8.0 Inch Axle)
Note: All axle assemblies are filled by volume of fluid during production. They are not filled to reach
a certain level. When checking the fluid level on any axle, variations in the readings can be caused
by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle
has just been driven before checking the fluid level, it may appear lower than normal because the
fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a
reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level
than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly
must be supported to get a true reading.
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks.
Repair as necessary. 4. Clean the area around the rear axle fill plug.
5. Remove the rear axle fill plug. 6. Inspect the lubricant level.
The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Service and Repair > Procedures > Page 5547
7. If the fluid level is low, add lubricant until the level is within specifications. Use the proper fluid.
Refer to Adhesives, Fluids, Lubricants, and
Sealers (See: Specifications/Fluid Type Specifications).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle.
Rear Axle Lubricant Level Inspection (8.6 Inch Axle)
Rear Axle Lubricant Level Inspection (8.6 Inch Axle)
Note: All axle assemblies are filled by volume of fluid during production. They are not filled to reach
a certain level. When checking the fluid level on any axle, variations in the readings can be caused
by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle
has just been driven before checking the fluid level, it may appear lower than normal because the
fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a
reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level
than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly
must be supported to get a true reading.
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks.
Repair as necessary. 4. Clean the area around the rear axle fill plug.
5. Remove the rear axle fill plug. 6. Inspect the lubricant level.
The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening.
7. If the fluid level is low, add lubricant until the level is within specifications. Use the proper fluid.
Refer to Adhesives, Fluids, Lubricants, and
Sealers (See: Specifications/Fluid Type Specifications).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Service and Repair > Procedures > Page 5548
Fluid - Differential: Removal and Replacement
Front Drive Axle
Front Axle Lubricant Replacement
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Ensure that the vehicle is level. 3. Remove the engine protection
shield (EPS), if equipped. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid
Plate/Service and Repair).
4. Remove the drain plug. 5. Drain axle fluid into a suitable container.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the drain plug and tighten to 32 Nm (24 lb ft). 7. Remove the fill plug. 8. Fill the drive axle
with the proper fluid. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service
Intervals). 9. Inspect the fluid level. Refer to Front Axle Lubricant Level Inspection (See:
Procedures/Front Drive Axle).
10. Install the fill plug and tighten to 32 Nm (24 lb ft). 11. Install the EPS, if equipped. Refer to
Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and
Repair). 12. Lower the vehicle.
Rear Axle Lubricant Replacement (8.0 Inch Axle)
Rear Axle Lubricant Replacement (8.0 Inch Axle)
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Clean the area around the rear axle fill plug. 3. Remove the rear axle
fill plug. 4. Remove the rear axle cover. Refer to Rear Axle Housing Cover and Gasket
Replacement (See: Differential Cover/Service and Repair). 5. Drain the lubricant into a suitable
container.
Installation Procedure
1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (See:
Differential Cover/Service and Repair). 2. Fill the rear axle with axle lubricant. Use the proper fluid.
Refer to Approximate Fluid Capacities (See: Maintenance/Service Intervals) and
Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 4. Lower the vehicle.
Rear Axle Lubricant Replacement (8.6 Inch Axle)
Rear Axle Lubricant Replacement (8.6 Inch Axle)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Service and Repair > Procedures > Page 5549
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Clean the area around the rear axle fill plug.
3. Remove the rear axle fill plug. 4. Remove the rear axle cover. Refer to Rear Axle Housing Cover
and Gasket Replacement (See: Differential Cover/Service and Repair). 5. Drain the lubricant into a
suitable container.
Installation Procedure
1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (See:
Differential Cover/Service and Repair). 2. Fill the rear axle with axle lubricant. Use the proper fluid.
Refer to Approximate Fluid Capacities (See: Maintenance/Service Intervals) and
Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution) /.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Service and Repair > Procedures > Page 5550
3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential >
Component Information > Service and Repair > Rear Drive Axle
Pinion Bearing: Service and Repair Rear Drive Axle
Drive Pinion Bearings Replacement (8.6 Inch Axle)
Special Tools
* DT 49032 - Pinion Bearing Cup Installer
* DT 49275 - Pinion Bearing Remover
* J 8092 - Universal Driver Handle 3/4 in-10
* J 22828 - Input Shaft Gear Installer
* J 22912-B - Bearing Remover
* J 28677 - Needle Bearing Installer
Disassemble Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the differential assembly. Refer to
Differential Replacement (See: Service and Repair/Removal and Replacement/Rear Drive
Axle/Differential Replacement).
3. Remove the differential drive pinion gear from the axle. Refer to Drive Pinion and Ring Gear
Replacement (See: Pinion Gear/Service and
Repair/Rear Drive Axle).
4. Using the DT 49275 - remover and the J 22912-B - puller , remove the differential drive pinion
gear bearing and the spacer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5555
Note: Position the brass drift in the slots provided in the axle housing. Move the drift back and forth
between one side of the cup and the other in order to work the cups out of the housing evenly.
5. Using a hammer and a brass drift, remove the outer differential drive pinion gear bearing cup.
Note: Position the brass drift in the slots provided in the axle housing. Move the drift back and forth
between one side of the cup and the other in order to work the cups out of the housing evenly.
6. Using a hammer and a brass drift, remove the inner differential drive pinion gear bearing cup.
Assemble Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5556
1. Using the J 28677 - installer (1) and the J 8092 - handle (2), install the outer differential drive
pinion gear bearing cup.
2. Using the DT 49032 - installer
(1) and the J 8092 - handle (2), install the inner differential drive pinion gear cup.
3. Determine the selective spacer thickness for the pinion. Refer to Pinion Depth Adjustment (8.0
Inch Axle) (See: Service and Repair/Removal and
Replacement/Rear Drive Axle/Pinion Depth Adjustment (8.0 Inch Axle))Pinion Depth Adjustment
(8.6 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Pinion Depth
Adjustment (8.6 Inch Axle)).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5557
4. Install the selective pinion spacer (1) on the pinion gear (2).
5. Using the J 22828 - installer and a hammer, install the differential drive pinion gear bearing and
the spacer.
Note: Use the proper fluid.
6. Lubricate the pinion bearings with axle lubricant. Refer to Adhesives, Fluids, Lubricants, and
Sealers (See: Specifications/Fluid Type
Specifications).
7. Install the differential drive pinion gear outer bearing into the axle housing. 8. Install the
differential drive pinion gear into the axle housing. 9. Install the NEW differential drive pinion gear
seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service
and Repair/Rear Drive Axle).
10. Install the differential assembly. Refer to Differential Replacement (See: Service and
Repair/Removal and Replacement/Rear Drive
Axle/Differential Replacement).
11. Fill the axle with lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement (8.0
Inch Axle) (See: Fluid - Differential/Service and
Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.0 Inch
Axle))Rear Axle Lubricant Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and
Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.6 Inch
Axle)).
12. Remove the support and lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5558
Pinion Bearing: Service and Repair Front Drive Axle
Drive Pinion Bearings Replacement
Special Tools
* J 5590 Pinion Bearing Race Installer - Rear
* J 7817 Outer Bearing Race Installer
* J 8092 Universal Driver Handle- 3/4 in - 10
* J 8614-01 Flange and Pulley Holding Tool
* J 21128 Axle Pinion Oil Seal Installer
* J 22912-B Split-Plate Bearing Puller
* J 29609 Rear Pinion Bearing Cup Installer
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Remove the differential carrier assembly. Refer to Differential Carrier
Assembly Replacement (See: Differential Carrier/Service and Repair). 3. Remove the drive pinion
from the axle. Refer to Drive Pinion and Ring Gear Replacement (See: Pinion Gear/Service and
Repair/Front Drive
Axle).
4. Press the bearing off of the pinion using the J 22912-B . 5. Remove the shim.
6. Remove the outer pinion bearing cup from the axle housing using a hammer and a brass drift in
the slots provided. Move the drift back and forth
between one side of the cup and the other in order to work the cups out of the housing evenly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5559
7. Remove the inner pinion bearing cup from the axle housing using a hammer and a brass drift in
the slots provided. Move the drift back and forth
between one side of the cup and the other in order to work the cups out of the housing evenly.
Installation Procedure
1. Install the outer pinion bearing cup using the J 7817 (1) and the J 8092 (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5560
2. Install the inner pinion bearing cup using the J 29609 (2) and the J 8092 (1). 3. Determine the
selective shim thickness for the pinion. Refer to Pinion Depth Adjustment (See: Service and
Repair/Removal and
Replacement/Front Drive Axle/Pinion Depth Adjustment).
4. Install the selective shim between the inner pinion bearing and the shoulder on the gear. 5.
Install the inner pinion bearing using the J 5590 .
Press the bearing on until the cone seats on the pinion shim.
6. Install a new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Use the
proper fluid. Refer to Fluid and Lubricant Recommendations (See:
Maintenance/Service Intervals).
8. Install the pinion into the axle housing. 9. Install the outer pinion bearing onto the pinion.
10. Install a new pinion oil seal using the J 21128 . 11. Apply sealant GM P/N 12346004 (Canadian
P/N 10953480) or equivalent to the splines of the pinion yoke.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5561
12. Install the pinion yoke.
Align the marks made during removal.
13. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few
pinion shaft threads show through the yoke. 14. Install the washer and a new pinion nut.
15. Install the J 8614-01 onto the pinion yoke as shown.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible
spacer installed.
16. Tighten the pinion nut while holding the J 8614-01 .
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening
the nut to seat the bearings.
17. Measure the rotating torque of the pinion using an inch-pound torque wrench.
The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4
Nm (15-30 lb in) for new bearings.
18. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15
lb in) for new bearings, continue to tighten the
pinion nut.
Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate
the pinion is 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new
bearings.
19. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings
have seated.
Recheck the rotating torque and adjust if necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5562
20. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement
(See: Differential Carrier/Service and Repair). 21. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential >
Component Information > Service and Repair > Front Drive Axle
Pinion Flange: Service and Repair Front Drive Axle
Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement
Special Tools
* J 8614-01 Flange and Pulley Holding Tool
* J 21128 Axle Pinion Oil Seal Installer
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Remove the engine protection shield (EPS). Refer to Engine
Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and
Repair).
3. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (See:
Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller
Shaft/Service and Repair/Front Propeller Shaft Replacement).
4. Remove the brake calipers. Refer to Brake Caliper Replacement (See: Brakes and Traction
Control/Disc Brake System/Brake Caliper/Service
and Repair/Brake Caliper Replacement).
5. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench.
Record the torque value for reassembly. This will
give the combined preload for the following components:
* The pinion bearings
* The pinion seal
* The carrier bearings
* The axle bearings
* The axle seals
6. Scribe an alignment line between the pinion shaft and the pinion yoke.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential >
Component Information > Service and Repair > Front Drive Axle > Page 5567
7. Install the J 8614-01 (1) onto the pinion as shown. 8. Remove the pinion nut while holding the J
8614-01 (1). 9. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
10. Remove the pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
Note: Carefully remove the seal from the bore. Do not distort or scratch the aluminum case.
11. Remove the oil seal using a suitable seal removal tool.
12. Remove the dust deflector from the pinion yoke using a soft-faced hammer.
Installation Procedure
1. Install the new deflector onto the pinion yoke using a soft-faced hammer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential >
Component Information > Service and Repair > Front Drive Axle > Page 5568
Important: Drive the seal in straight, not at an angle, as this will damage the aluminum housing.
2. Install the new oil seal by doing the following:
1. Position the oil seal in the bore. 2. Install the J 21128 over the oil seal. 3. Strike the J 21128 with
a hammer until the seal flange seats on the axle housing surface.
3. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the
drive pinion yoke. 4. Install the pinion yoke.
Align the reference marks made during removal.
Caution: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be
damaged if the pinion flange/yoke is hammered onto the pinion shaft.
5. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few
pinion shaft threads show through the yoke. 6. Install the washer and a new pinion nut.
7. Install the J 8614-01 (1) onto the pinion yoke as shown.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible
spacer installed.
8. Tighten the pinion nut while holding the J 8614-01 (1).
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening
the nut to seat the bearings.
9. Measure the rotating torque of the pinion using an inch-pound torque wrench.
Compare the measurement of the rotating torque to the measurement recorded earlier.
The rotating torque of the pinion nut should be 0.40-0.57 Nm (3-5 lb in) greater than the torque
recorded during removal.
10. If the rotating torque is not within specifications, continue to tighten the pinion nut.
Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate
the pinion is 0.40-0.57 Nm (3-5 lb in) greater than the torque recorded during removal.
11. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings
have seated. Recheck the rotating torque and adjust if
necessary.
12. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See:
Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller
Shaft/Service and Repair/Front Propeller Shaft Replacement).
13. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid Plate/Service and Repair). 14. Install the brake calipers. Refer to Brake Caliper
Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and
Repair/Brake Caliper Replacement).
15. Inspect the axle lubricant level, and add, if necessary. Refer to Front Axle Lubricant
Replacement (See: Fluid - Differential/Service and
Repair/Removal and Replacement/Front Drive Axle).
16. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential >
Component Information > Service and Repair > Front Drive Axle > Page 5569
Pinion Flange: Service and Repair Rear Drive Axle
Drive Pinion Flange/Yoke and/or Oil Seal Replacement
Special Tools
* J 8614-01 - Flange Holder and Remover
* J 33782 - Pinion Oil Seal Installer
* J 38694 - Extension Housing Oil Pump/Seal Installer
Removal Procedure
Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft
and the axles, prior to disassembly. These components include the propeller shafts, drive axles,
pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you
removed the parts. Follow any specifications, torque values, and any measurements made prior to
disassembly
1. Raise the and support vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear drum brakes. Refer to Brake
Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service
and Repair/Removal and Replacement).
3. Remove the propeller shaft.
* For vehicles equipped with one piece propeller shafts, refer to One-Piece Propeller Shaft
Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and
Repair/One-Piece Propeller Shaft Replacement).
* For vehicles equipped with two piece propeller shafts, refer to Two-Piece Propeller Shaft
Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and
Repair/Two-Piece Propeller Shaft Replacement).
4. Use an inch-pound torque wrench, measure the amount of torque required to rotate the pinion.
Record this measurement for reassembly. This will
give the combined preload for the following components:
* The pinion bearings
* The pinion oil seal
* The differential case bearings
* The axle bearings
* The axle seals
5. Place an alignment mark between the pinion and the pinion yoke.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential >
Component Information > Service and Repair > Front Drive Axle > Page 5570
6. Using the J 8614-01 - tool to hold the pinion nut, remove the pinion nut and the washer.
Note: Use a container in order to retrieve the lubricant.
7. Using the J 8614-01 - tool (1) to hold the pinion yoke, remove the pinion yoke by turning the J
8614-3 (3) clockwise.
Note: Do not damage the housing.
8. Using a suitable tool, remove the pinion oil seal.
Installation Procedure
1. Using the J 33782 - installer for the 8.0 inch, install the pinion seal. 2. Apply sealant to the
splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers (See:
Specifications/Fluid Type
Specifications).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential >
Component Information > Service and Repair > Front Drive Axle > Page 5571
3. Align the reference marks and install the pinion yoke.
Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be
damaged if the pinion flange/yoke is hammered onto the pinion shaft.
4. Using a soft-faced hammer, tap the pinion yoke until the threads on the pinion shaft can be seen.
5. Install the washer and a NEW pinion nut.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. While holding the J 8614-01 - tool , tighten the NEW pinion nut in small increments until the end
play is just taken up.
Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible
spacer installed.
Note: Compare this measurement with the rotating torque recorded during removal.
7. Using an inch pound torque wrench, measure the rotating torque of the pinion0.40-0.57 Nm (3-5
lb in) greater than the rotating torque
recorded during removal..
8. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings
have seated. Recheck the rotating torque and adjust if
necessary.
9. Install the propeller shaft.
* For vehicles equipped with one piece propeller shafts, refer to One-Piece Propeller Shaft
Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and
Repair/One-Piece Propeller Shaft Replacement).
* For vehicles equipped with two piece propeller shafts, refer to Two-Piece Propeller Shaft
Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and
Repair/Two-Piece Propeller Shaft Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential >
Component Information > Service and Repair > Front Drive Axle > Page 5572
10. Install the rear brake rotors. Refer to Brake Drum Replacement (See: Brakes and Traction
Control/Drum Brake System/Brake Drum/Service and
Repair/Removal and Replacement).
11. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant
Replacement (8.0 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant
Replacement (8.0 Inch Axle))Rear Axle Lubricant Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant
Replacement (8.6 Inch Axle)).
12. Remove the support and lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential >
Component Information > Service and Repair > Rear Drive Axle
Pinion Gear: Service and Repair Rear Drive Axle
Drive Pinion and Ring Gear Replacement
Special Tools
* J 8614-01 Flange and Pulley Holding Tool
* J 22536 Pinion Driver
* J 38694 Extension Housing Oil Pump/Seal Installer
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Remove the axle shafts. Refer to Rear Axle Shaft Replacement
(See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service
and Repair).
3. Remove the differential assembly. Refer to Differential Replacement (See: Service and
Repair/Removal and Replacement/Rear Drive
Axle/Differential Replacement).
4. Remove the drive pinion yoke and the oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal
Replacement (See: Pinion Flange/Service and
Repair/Rear Drive Axle).
5. Install the J 22536 as shown.
Ensure that the J 22536 is firmly seated on the pinion.
6. Drive the pinion out using the J 22536 and a hammer.
Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.
7. Remove the collapsible spacer from the pinion. Discard the spacer. 8. Remove the pinion
bearings and the cups. Refer to Drive Pinion Bearings Replacement (8.6 Inch Axle) (See: Pinion
Bearing/Service and
Repair/Rear Drive Axle)Drive Pinion Bearings Replacement (8.0 Inch Axle) (See: Service and
Repair/Removal and Replacement/Rear Drive Axle/Drive Pinion Bearings Replacement (8.0 Inch
Axle)).
9. Remove the left-hand threaded ring gear bolts. Discard the bolts.
10. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5577
Note: The mating surface of the ring gear and the differential case must be clean and free of burrs
before installing the ring gear.
1. Install the ring gear to the differential case. 2. Install the new ring gear bolts.
Hand start each bolt to ensure that the ring gear is properly installed to the differential case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the new ring gear bolts alternately and in stages, gradually pulling the ring gear onto the
differential case.
Tighten the ring gear bolts in sequence to 120 Nm (89 lb ft).
4. Install the drive pinion bearing cups. Refer to Drive Pinion Bearings Replacement (8.6 Inch Axle)
(See: Pinion Bearing/Service and Repair/Rear
Drive Axle)Drive Pinion Bearings Replacement (8.0 Inch Axle) (See: Service and Repair/Removal
and Replacement/Rear Drive Axle/Drive Pinion Bearings Replacement (8.0 Inch Axle)).
5. Determine the selective shim thickness for the pinion gear. Refer to Pinion Depth Adjustment
(8.0 Inch Axle) (See: Service and Repair/Removal
and Replacement/Rear Drive Axle/Pinion Depth Adjustment (8.0 Inch Axle))Pinion Depth
Adjustment (8.6 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive
Axle/Pinion Depth Adjustment (8.6 Inch Axle)).
6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing onto the pinion. Refer
to Drive Pinion Bearings Replacement (8.6 Inch Axle) (See: Pinion Bearing/Service and
Repair/Rear Drive Axle)Drive Pinion Bearings Replacement (8.0 Inch Axle) (See: Service and
Repair/Removal and Replacement/Rear Drive Axle/Drive Pinion Bearings Replacement (8.0 Inch
Axle)).
8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. Refer to
Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals).
10. Install the pinion to the axle housing. 11. Install the outer pinion bearing.
12. Install a new pinion oil seal using the J 38694 . 13. Apply sealant, GM P/N 12346004
(Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5578
14. Install the pinion yoke.
Align the marks made during removal.
15. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few
pinion shaft threads show through the yoke. 16. Install the washer and a new pinion nut.
17. Install the J 8614-01 onto the pinion yoke as shown.
Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible
spacer installed.
18. Install the pinion yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See:
Pinion Flange/Service and Repair/Rear Drive Axle
).
19. Install the differential. Refer to Differential Replacement (See: Service and Repair/Removal and
Replacement/Rear Drive Axle/Differential
Replacement).
20. Perform a gear tooth contact pattern check on the pinion and the ring gear. Refer to Gear Tooth
Contact Pattern Inspection (See: Service and
Repair/Removal and Replacement/Rear Drive Axle/Gear Tooth Contact Pattern Inspection).
21. Install the axle shafts. Refer to Rear Axle Shaft Replacement (See: Drive Axles, Bearings and
Joints/Axle Shaft Assembly/Axle Shaft/Service and
Repair).
22. Fill the axle with axle lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement
(8.0 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant
Replacement (8.0 Inch Axle))Rear Axle Lubricant Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant
Replacement (8.6 Inch Axle)).
23. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5579
Pinion Gear: Service and Repair Front Drive Axle
Drive Pinion and Ring Gear Replacement
Special Tools
* J 8001 Dial Indicator Set
* J 8614-01 Flange and Pulley Holding Tool
* J 21128 Axle Pinion Oil Seal Installer
* J 22536 Pinion Driver
* J 22779 Side Bearing Backlash Gage
* J 25025 Guide Pins
* J 25588 Side Bearing Shim Installer
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Remove the differential carrier assembly. Refer to Differential Carrier
Assembly Replacement (See: Differential Carrier/Service and Repair). 3. Remove the drive pinion
yoke and the oil seal. Refer to Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector
Replacement (See:
Pinion Flange/Service and Repair/Front Drive Axle).
4. Install the J 22536 as shown.
Ensure that the J 22536 is firmly seated on the pinion.
5. Drive the pinion out using the J 22536 and a hammer.
Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.
6. Remove the collapsible spacer from the pinion. Discard the spacer. 7. Remove the pinion
bearings and the cups. Refer to Drive Pinion Bearings Replacement (See: Pinion Bearing/Service
and Repair/Front Drive
Axle).
8. Remove the ring gear. Refer to Front Differential Case Disassemble (See: Service and
Repair/Removal and Replacement/Front Drive Axle/Front
Differential Case Disassemble).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5580
Note: The mating surface of the ring gear and the differential case must be clean and free of burrs
before installing the ring gear.
1. Install the ring gear to the differential case. Refer to Front Differential Case Disassemble (See:
Service and Repair/Removal and
Replacement/Front Drive Axle/Front Differential Case Disassemble).
2. Install the new ring gear bolts.
Hand start each bolt to ensure that the ring gear is properly installed to the differential case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the new ring gear bolts alternately and in stages, gradually pulling the ring gear onto the
differential case.
Tighten the ring gear bolts in sequence to 120 Nm (89 lb ft).
4. Install the drive pinion bearing cups. Refer to Drive Pinion Bearings Replacement (See: Pinion
Bearing/Service and Repair/Front Drive Axle). 5. Determine the selective shim thickness for the
pinion gear. See Differential Side Bearing Preload Adjustment Procedure below. 6. Install the
selective shim onto the pinion. 7. Install the inner pinion bearing onto the pinion. Refer to Drive
Pinion Bearings Replacement (See: Pinion Bearing/Service and Repair/Front
Drive Axle).
8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. Refer to
Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals).
10. Install the pinion to the axle housing. 11. Install the outer pinion bearing.
12. Install a new pinion oil seal using the J 21128 . 13. Apply sealant, GM P/N 12346004
(Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5581
14. Install the pinion yoke.
Align the marks made during removal.
15. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few
pinion shaft threads show through the yoke. 16. Install the washer and a new pinion nut.
17. Install the J 8614-01 onto the pinion yoke as shown.
Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible
spacer installed.
18. Tighten the pinion nut while holding the J 8614-01 .
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening
the nut to seat the bearings.
19. Measure the rotating torque of the pinion using an inch-pound torque wrench.
The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings or 1.7-3.4
Nm (15-30 lb in) for new bearings.
20. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15
lb in) for new bearings, continue to tighten the
pinion nut. Tighten the pinion nut, in small increments, as needed, until the torque required in order
to rotate the pinion is 1.0-2.3 Nm (10-20 lb in) for used bearings or 1.7-3.4 Nm (15-30 lb in) for new
bearings.
21. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings
have seated.
Recheck the rotating torque and adjust if necessary.
22. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement
(See: Differential Carrier/Service and Repair). 23. Perform a gear tooth contact pattern check on
the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection (See: Service and
Repair/Removal and Replacement/Front Drive Axle/Gear Tooth Contact Pattern Inspection).
24. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5582
Differential Side Bearing Preload Adjustment Procedure
Important:
* The differential side bearing preload adjustment must be completed before the backlash
adjustment can be started.
* In order to maintain the original backlash, adjust the differential case side bearing preload by
changing the thickness of the left and the right side shim packs equally.
* Measure the service shims and the spacers one at a time. Add the measurements together in
order to obtain the total thickness of the left or the right side shim pack.
* Do not use or reuse the original cast iron production shims. Use service shims and spacers
instead.
1. Install the drive pinion, if necessary. Refer to Drive Pinion and Ring Gear Replacement (See:
Rear Drive Axle). 2. Measure the rotating torque of the drive pinion using an inch-pound torque
wrench.
The rotating torque of the drive pinion should be 1.7-3.4 Nm (15-30 lb in) for new bearings or
1.1-2.3 Nm(10-20 lb in) for used bearings.
3. Record the measurement.
Important: Before installation of the differential assembly, ensure that the side bearing surfaces in
the axle housing are clean and free of burrs. If the original bearings are to be reused, the original
bearing cups must also be used.
4. Install the differential assembly with the side bearings and bearing cups into the axle housing. 5.
Insert one 4.318 mm (0.170 in) thick service spacer into the left side of the axle housing. 6. Side
the differential assembly towards the service spacer in order to hold the spacer in place. 7. Install
the J 22779 between the right side differential side bearing cup and the axle housing.
Important: Over-tightening may spread the housing and result in incorrect shim selection.
8. Tighten the knob on the J 22779 until there is moderate drag when the J 22779 is moved. 9.
Remove the J 22779 .
10. Remove the service spacer. 11. Using a micrometer, measure the thickness of the J 22779 in 3
locations. 12. Calculate the average of the 3 measurements.
Record the measurement.
13. Using a micrometer, measure the thickness of the service spacer.
Record the measurement.
14. Add the thickness of the service spacer to the average thickness of the J 22779 .
The resulting value is the total service shim thickness without preload for the axle.
15. Insert one 1.016 mm (0.040 in) service shim between the right side differential side bearing cup
and the axle housing. 16. Insert one BENT 1.016 mm (0.040 in) service shim between the right
side differential side bearing cup and the service shim. 17. Install the J 22779 on the left side of the
differential assembly. 18. While rotating the ring gear back and forth, tighten the knob on the J
22779 until there is approximately 0.025-0.051 mm (0.001-0.002 in) of
backlash between the ring gear and the drive pinion.
19. Once the amount of backlash is obtained, remove the J 22779 . 20. Remove the differential
case with the differential side bearings and the bearing cups. 21. Remove the service shims. 22.
Using a micrometer, measure the thickness of the J 22779 in 3 locations. 23. Calculate the average
of the 3 measurements.
This value is the left side service shim thickness without preload.
24. Subtract the service shim thickness for the left side of the axle, calculated in step 23, from the
total service shim thickness, calculated in step 14.
This value is the service shim thickness for the right side of the axle without preload.
25. In order to initially set the preload of the differential side bearings and the backlash to
approximately 0.013-0.023 mm (0.005-0.009 in), take the
value determined in step 24 and add 0.0203 mm (0.008 in) service shim thickness to this amount.
26. Assemble the left side shim pack using one 4.318 mm (0.170 in) service spacer and the
appropriate amount of selective service shims equaling the
thickness determined in step 23. Measure the service spacer and the service shims separately.
Add the measurements together in order to determine the total shim pack thickness.
27. Assemble the right side shim pack using one 4.318 mm (0.170 in) service spacer and the
appropriate amount of selective service shims equaling
the thickness determined in step 25. Measure the service spacer and the service shims separately.
Add the measurements together in order to determine the total shim pack thickness.
28. Install the differential assembly with the differential side bearings and the differential side
bearing cups.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential >
Component Information > Service and Repair > Rear Drive Axle > Page 5583
29. Install the left side service spacer between the axle housing and the differential assembly. 30.
Install the left side selective service shim or shims.
The service shim or shims must be installed between the service spacer and the differential side
bearing cup.
31. Install the right side service spacer between the axle housing and the differential assembly. 32.
Install the right side selective service shim or shims using the J 25588 , if necessary.
The service shim or shims must be installed between the service spacer and the differential side
bearing cup.
33. Install the differential bearing caps and the bolts.
Tighten the differential bearing cap bolts to 63 Nm (46 lb ft).
34. Measure the drive pinion and differential side bearing preload using an inch-pound torque
wrench.
Rotate the pinion several times to ensure the differential side bearings have seated.
The rotating torque of the drive pinion and differential side bearings should be 3.9-6.2 Nm (30-55 lb
in) for new bearings or 2.8-5.1 Nm (25-45 lb in) for used bearings.
Record the measurement.
35. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured
in Step 2, from the drive pinion and differential
case bearing preload, measured in Step 33. Multiply the value obtained by the axle ratio.
The differential case side bearing preload should be 1.7-4.0 Nm (15-35 lb in).
36. If the differential side bearing preload is not within specifications, add or subtract shim
thickness equally from each shim pack as necessary in
order to increase/decrease the side bearing preload.
37. Once the differential side bearing preload is correct, measure the backlash and adjust, if
necessary. Refer to Backlash Inspection and Adjustment
(See: Service and Repair/Removal and Replacement/Front Drive Axle/Backlash Inspection and
Adjustment).
38. Once the differential side bearing preload and backlash is correct, perform a gear tooth contact
pattern check in order to ensure proper alignment
between the ring and pinion gears. Refer to Gear Tooth Contact Pattern Inspection (See: Service
and Repair/Removal and Replacement/Front Drive Axle/Gear Tooth Contact Pattern Inspection).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Rear Drive Axle
Ring Gear: Service and Repair Rear Drive Axle
Drive Pinion and Ring Gear Replacement
Special Tools
* J 8614-01 Flange and Pulley Holding Tool
* J 22536 Pinion Driver
* J 38694 Extension Housing Oil Pump/Seal Installer
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Remove the axle shafts. Refer to Rear Axle Shaft Replacement
(See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service
and Repair).
3. Remove the differential assembly. Refer to Differential Replacement (See: Service and
Repair/Removal and Replacement/Rear Drive
Axle/Differential Replacement).
4. Remove the drive pinion yoke and the oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal
Replacement (See: Pinion Flange/Service and
Repair/Rear Drive Axle).
5. Install the J 22536 as shown.
Ensure that the J 22536 is firmly seated on the pinion.
6. Drive the pinion out using the J 22536 and a hammer.
Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.
7. Remove the collapsible spacer from the pinion. Discard the spacer. 8. Remove the pinion
bearings and the cups. Refer to Drive Pinion Bearings Replacement (8.6 Inch Axle) (See: Pinion
Bearing/Service and
Repair/Rear Drive Axle)Drive Pinion Bearings Replacement (8.0 Inch Axle) (See: Service and
Repair/Removal and Replacement/Rear Drive Axle/Drive Pinion Bearings Replacement (8.0 Inch
Axle)).
9. Remove the left-hand threaded ring gear bolts. Discard the bolts.
10. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Rear Drive Axle > Page 5588
Note: The mating surface of the ring gear and the differential case must be clean and free of burrs
before installing the ring gear.
1. Install the ring gear to the differential case. 2. Install the new ring gear bolts.
Hand start each bolt to ensure that the ring gear is properly installed to the differential case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the new ring gear bolts alternately and in stages, gradually pulling the ring gear onto the
differential case.
Tighten the ring gear bolts in sequence to 120 Nm (89 lb ft).
4. Install the drive pinion bearing cups. Refer to Drive Pinion Bearings Replacement (8.6 Inch Axle)
(See: Pinion Bearing/Service and Repair/Rear
Drive Axle)Drive Pinion Bearings Replacement (8.0 Inch Axle) (See: Service and Repair/Removal
and Replacement/Rear Drive Axle/Drive Pinion Bearings Replacement (8.0 Inch Axle)).
5. Determine the selective shim thickness for the pinion gear. Refer to Pinion Depth Adjustment
(8.0 Inch Axle) (See: Service and Repair/Removal
and Replacement/Rear Drive Axle/Pinion Depth Adjustment (8.0 Inch Axle))Pinion Depth
Adjustment (8.6 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive
Axle/Pinion Depth Adjustment (8.6 Inch Axle)).
6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing onto the pinion. Refer
to Drive Pinion Bearings Replacement (8.6 Inch Axle) (See: Pinion Bearing/Service and
Repair/Rear Drive Axle)Drive Pinion Bearings Replacement (8.0 Inch Axle) (See: Service and
Repair/Removal and Replacement/Rear Drive Axle/Drive Pinion Bearings Replacement (8.0 Inch
Axle)).
8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. Refer to
Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals).
10. Install the pinion to the axle housing. 11. Install the outer pinion bearing.
12. Install a new pinion oil seal using the J 38694 . 13. Apply sealant, GM P/N 12346004
(Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Rear Drive Axle > Page 5589
14. Install the pinion yoke.
Align the marks made during removal.
15. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few
pinion shaft threads show through the yoke. 16. Install the washer and a new pinion nut.
17. Install the J 8614-01 onto the pinion yoke as shown.
Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible
spacer installed.
18. Install the pinion yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See:
Pinion Flange/Service and Repair/Rear Drive Axle
).
19. Install the differential. Refer to Differential Replacement (See: Service and Repair/Removal and
Replacement/Rear Drive Axle/Differential
Replacement).
20. Perform a gear tooth contact pattern check on the pinion and the ring gear. Refer to Gear Tooth
Contact Pattern Inspection (See: Service and
Repair/Removal and Replacement/Rear Drive Axle/Gear Tooth Contact Pattern Inspection).
21. Install the axle shafts. Refer to Rear Axle Shaft Replacement (See: Drive Axles, Bearings and
Joints/Axle Shaft Assembly/Axle Shaft/Service and
Repair).
22. Fill the axle with axle lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement
(8.0 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant
Replacement (8.0 Inch Axle))Rear Axle Lubricant Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant
Replacement (8.6 Inch Axle)).
23. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Rear Drive Axle > Page 5590
Ring Gear: Service and Repair Front Drive Axle
Drive Pinion and Ring Gear Replacement
Special Tools
* J 8001 Dial Indicator Set
* J 8614-01 Flange and Pulley Holding Tool
* J 21128 Axle Pinion Oil Seal Installer
* J 22536 Pinion Driver
* J 22779 Side Bearing Backlash Gage
* J 25025 Guide Pins
* J 25588 Side Bearing Shim Installer
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Remove the differential carrier assembly. Refer to Differential Carrier
Assembly Replacement (See: Differential Carrier/Service and Repair). 3. Remove the drive pinion
yoke and the oil seal. Refer to Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector
Replacement (See:
Pinion Flange/Service and Repair/Front Drive Axle).
4. Install the J 22536 as shown.
Ensure that the J 22536 is firmly seated on the pinion.
5. Drive the pinion out using the J 22536 and a hammer.
Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.
6. Remove the collapsible spacer from the pinion. Discard the spacer. 7. Remove the pinion
bearings and the cups. Refer to Drive Pinion Bearings Replacement (See: Pinion Bearing/Service
and Repair/Front Drive
Axle).
8. Remove the ring gear. Refer to Front Differential Case Disassemble (See: Service and
Repair/Removal and Replacement/Front Drive Axle/Front
Differential Case Disassemble).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Rear Drive Axle > Page 5591
Note: The mating surface of the ring gear and the differential case must be clean and free of burrs
before installing the ring gear.
1. Install the ring gear to the differential case. Refer to Front Differential Case Disassemble (See:
Service and Repair/Removal and
Replacement/Front Drive Axle/Front Differential Case Disassemble).
2. Install the new ring gear bolts.
Hand start each bolt to ensure that the ring gear is properly installed to the differential case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the new ring gear bolts alternately and in stages, gradually pulling the ring gear onto the
differential case.
Tighten the ring gear bolts in sequence to 120 Nm (89 lb ft).
4. Install the drive pinion bearing cups. Refer to Drive Pinion Bearings Replacement (See: Pinion
Bearing/Service and Repair/Front Drive Axle). 5. Determine the selective shim thickness for the
pinion gear. See Differential Side Bearing Preload Adjustment Procedure below. 6. Install the
selective shim onto the pinion. 7. Install the inner pinion bearing onto the pinion. Refer to Drive
Pinion Bearings Replacement (See: Pinion Bearing/Service and Repair/Front
Drive Axle).
8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. Refer to
Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals).
10. Install the pinion to the axle housing. 11. Install the outer pinion bearing.
12. Install a new pinion oil seal using the J 21128 . 13. Apply sealant, GM P/N 12346004
(Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Rear Drive Axle > Page 5592
14. Install the pinion yoke.
Align the marks made during removal.
15. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few
pinion shaft threads show through the yoke. 16. Install the washer and a new pinion nut.
17. Install the J 8614-01 onto the pinion yoke as shown.
Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible
spacer installed.
18. Tighten the pinion nut while holding the J 8614-01 .
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening
the nut to seat the bearings.
19. Measure the rotating torque of the pinion using an inch-pound torque wrench.
The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings or 1.7-3.4
Nm (15-30 lb in) for new bearings.
20. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15
lb in) for new bearings, continue to tighten the
pinion nut. Tighten the pinion nut, in small increments, as needed, until the torque required in order
to rotate the pinion is 1.0-2.3 Nm (10-20 lb in) for used bearings or 1.7-3.4 Nm (15-30 lb in) for new
bearings.
21. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings
have seated.
Recheck the rotating torque and adjust if necessary.
22. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement
(See: Differential Carrier/Service and Repair). 23. Perform a gear tooth contact pattern check on
the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection (See: Service and
Repair/Removal and Replacement/Front Drive Axle/Gear Tooth Contact Pattern Inspection).
24. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Rear Drive Axle > Page 5593
Differential Side Bearing Preload Adjustment Procedure
Important:
* The differential side bearing preload adjustment must be completed before the backlash
adjustment can be started.
* In order to maintain the original backlash, adjust the differential case side bearing preload by
changing the thickness of the left and the right side shim packs equally.
* Measure the service shims and the spacers one at a time. Add the measurements together in
order to obtain the total thickness of the left or the right side shim pack.
* Do not use or reuse the original cast iron production shims. Use service shims and spacers
instead.
1. Install the drive pinion, if necessary. Refer to Drive Pinion and Ring Gear Replacement (See:
Pinion Gear/Service and Repair/Rear Drive Axle). 2. Measure the rotating torque of the drive pinion
using an inch-pound torque wrench.
The rotating torque of the drive pinion should be 1.7-3.4 Nm (15-30 lb in) for new bearings or
1.1-2.3 Nm(10-20 lb in) for used bearings.
3. Record the measurement.
Important: Before installation of the differential assembly, ensure that the side bearing surfaces in
the axle housing are clean and free of burrs. If the original bearings are to be reused, the original
bearing cups must also be used.
4. Install the differential assembly with the side bearings and bearing cups into the axle housing. 5.
Insert one 4.318 mm (0.170 in) thick service spacer into the left side of the axle housing. 6. Side
the differential assembly towards the service spacer in order to hold the spacer in place. 7. Install
the J 22779 between the right side differential side bearing cup and the axle housing.
Important: Over-tightening may spread the housing and result in incorrect shim selection.
8. Tighten the knob on the J 22779 until there is moderate drag when the J 22779 is moved. 9.
Remove the J 22779 .
10. Remove the service spacer. 11. Using a micrometer, measure the thickness of the J 22779 in 3
locations. 12. Calculate the average of the 3 measurements.
Record the measurement.
13. Using a micrometer, measure the thickness of the service spacer.
Record the measurement.
14. Add the thickness of the service spacer to the average thickness of the J 22779 .
The resulting value is the total service shim thickness without preload for the axle.
15. Insert one 1.016 mm (0.040 in) service shim between the right side differential side bearing cup
and the axle housing. 16. Insert one BENT 1.016 mm (0.040 in) service shim between the right
side differential side bearing cup and the service shim. 17. Install the J 22779 on the left side of the
differential assembly. 18. While rotating the ring gear back and forth, tighten the knob on the J
22779 until there is approximately 0.025-0.051 mm (0.001-0.002 in) of
backlash between the ring gear and the drive pinion.
19. Once the amount of backlash is obtained, remove the J 22779 . 20. Remove the differential
case with the differential side bearings and the bearing cups. 21. Remove the service shims. 22.
Using a micrometer, measure the thickness of the J 22779 in 3 locations. 23. Calculate the average
of the 3 measurements.
This value is the left side service shim thickness without preload.
24. Subtract the service shim thickness for the left side of the axle, calculated in step 23, from the
total service shim thickness, calculated in step 14.
This value is the service shim thickness for the right side of the axle without preload.
25. In order to initially set the preload of the differential side bearings and the backlash to
approximately 0.013-0.023 mm (0.005-0.009 in), take the
value determined in step 24 and add 0.0203 mm (0.008 in) service shim thickness to this amount.
26. Assemble the left side shim pack using one 4.318 mm (0.170 in) service spacer and the
appropriate amount of selective service shims equaling the
thickness determined in step 23. Measure the service spacer and the service shims separately.
Add the measurements together in order to determine the total shim pack thickness.
27. Assemble the right side shim pack using one 4.318 mm (0.170 in) service spacer and the
appropriate amount of selective service shims equaling
the thickness determined in step 25. Measure the service spacer and the service shims separately.
Add the measurements together in order to determine the total shim pack thickness.
28. Install the differential assembly with the differential side bearings and the differential side
bearing cups.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Rear Drive Axle > Page 5594
29. Install the left side service spacer between the axle housing and the differential assembly. 30.
Install the left side selective service shim or shims.
The service shim or shims must be installed between the service spacer and the differential side
bearing cup.
31. Install the right side service spacer between the axle housing and the differential assembly. 32.
Install the right side selective service shim or shims using the J 25588 , if necessary.
The service shim or shims must be installed between the service spacer and the differential side
bearing cup.
33. Install the differential bearing caps and the bolts.
Tighten the differential bearing cap bolts to 63 Nm (46 lb ft).
34. Measure the drive pinion and differential side bearing preload using an inch-pound torque
wrench.
Rotate the pinion several times to ensure the differential side bearings have seated.
The rotating torque of the drive pinion and differential side bearings should be 3.9-6.2 Nm (30-55 lb
in) for new bearings or 2.8-5.1 Nm (25-45 lb in) for used bearings.
Record the measurement.
35. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured
in Step 2, from the drive pinion and differential
case bearing preload, measured in Step 33. Multiply the value obtained by the axle ratio.
The differential case side bearing preload should be 1.7-4.0 Nm (15-35 lb in).
36. If the differential side bearing preload is not within specifications, add or subtract shim
thickness equally from each shim pack as necessary in
order to increase/decrease the side bearing preload.
37. Once the differential side bearing preload is correct, measure the backlash and adjust, if
necessary. Refer to Backlash Inspection and Adjustment
(See: Service and Repair/Removal and Replacement/Front Drive Axle/Backlash Inspection and
Adjustment).
38. Once the differential side bearing preload and backlash is correct, perform a gear tooth contact
pattern check in order to ensure proper alignment
between the ring and pinion gears. Refer to Gear Tooth Contact Pattern Inspection (See: Service
and Repair/Removal and Replacement/Front Drive Axle/Gear Tooth Contact Pattern Inspection).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential >
System Information > Service and Repair > Front Drive Axle
Seals and Gaskets: Service and Repair Front Drive Axle
Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement
Special Tools
* J 8614-01 Flange and Pulley Holding Tool
* J 21128 Axle Pinion Oil Seal Installer
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Remove the engine protection shield (EPS). Refer to Engine
Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and
Repair).
3. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (See:
Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller
Shaft/Service and Repair/Front Propeller Shaft Replacement).
4. Remove the brake calipers. Refer to Brake Caliper Replacement (See: Brakes and Traction
Control/Disc Brake System/Brake Caliper/Service
and Repair/Brake Caliper Replacement).
5. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench.
Record the torque value for reassembly. This will
give the combined preload for the following components:
* The pinion bearings
* The pinion seal
* The carrier bearings
* The axle bearings
* The axle seals
6. Scribe an alignment line between the pinion shaft and the pinion yoke.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential >
System Information > Service and Repair > Front Drive Axle > Page 5599
7. Install the J 8614-01 (1) onto the pinion as shown. 8. Remove the pinion nut while holding the J
8614-01 (1). 9. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
10. Remove the pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
Note: Carefully remove the seal from the bore. Do not distort or scratch the aluminum case.
11. Remove the oil seal using a suitable seal removal tool.
12. Remove the dust deflector from the pinion yoke using a soft-faced hammer.
Installation Procedure
1. Install the new deflector onto the pinion yoke using a soft-faced hammer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential >
System Information > Service and Repair > Front Drive Axle > Page 5600
Important: Drive the seal in straight, not at an angle, as this will damage the aluminum housing.
2. Install the new oil seal by doing the following:
1. Position the oil seal in the bore. 2. Install the J 21128 over the oil seal. 3. Strike the J 21128 with
a hammer until the seal flange seats on the axle housing surface.
3. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the
drive pinion yoke. 4. Install the pinion yoke.
Align the reference marks made during removal.
Caution: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be
damaged if the pinion flange/yoke is hammered onto the pinion shaft.
5. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few
pinion shaft threads show through the yoke. 6. Install the washer and a new pinion nut.
7. Install the J 8614-01 (1) onto the pinion yoke as shown.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible
spacer installed.
8. Tighten the pinion nut while holding the J 8614-01 (1).
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening
the nut to seat the bearings.
9. Measure the rotating torque of the pinion using an inch-pound torque wrench.
Compare the measurement of the rotating torque to the measurement recorded earlier.
The rotating torque of the pinion nut should be 0.40-0.57 Nm (3-5 lb in) greater than the torque
recorded during removal.
10. If the rotating torque is not within specifications, continue to tighten the pinion nut.
Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate
the pinion is 0.40-0.57 Nm (3-5 lb in) greater than the torque recorded during removal.
11. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings
have seated. Recheck the rotating torque and adjust if
necessary.
12. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See:
Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller
Shaft/Service and Repair/Front Propeller Shaft Replacement).
13. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid Plate/Service and Repair). 14. Install the brake calipers. Refer to Brake Caliper
Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and
Repair/Brake Caliper Replacement).
15. Inspect the axle lubricant level, and add, if necessary. Refer to Front Axle Lubricant
Replacement (See: Fluid - Differential/Service and
Repair/Removal and Replacement/Front Drive Axle).
16. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential >
System Information > Service and Repair > Front Drive Axle > Page 5601
Seals and Gaskets: Service and Repair Rear Drive Axle
Drive Pinion Flange/Yoke and/or Oil Seal Replacement
Special Tools
* J 8614-01 - Flange Holder and Remover
* J 33782 - Pinion Oil Seal Installer
* J 38694 - Extension Housing Oil Pump/Seal Installer
Removal Procedure
Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft
and the axles, prior to disassembly. These components include the propeller shafts, drive axles,
pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you
removed the parts. Follow any specifications, torque values, and any measurements made prior to
disassembly
1. Raise the and support vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear drum brakes. Refer to Brake
Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service
and Repair/Removal and Replacement).
3. Remove the propeller shaft.
* For vehicles equipped with one piece propeller shafts, refer to One-Piece Propeller Shaft
Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and
Repair/One-Piece Propeller Shaft Replacement).
* For vehicles equipped with two piece propeller shafts, refer to Two-Piece Propeller Shaft
Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and
Repair/Two-Piece Propeller Shaft Replacement).
4. Use an inch-pound torque wrench, measure the amount of torque required to rotate the pinion.
Record this measurement for reassembly. This will
give the combined preload for the following components:
* The pinion bearings
* The pinion oil seal
* The differential case bearings
* The axle bearings
* The axle seals
5. Place an alignment mark between the pinion and the pinion yoke.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential >
System Information > Service and Repair > Front Drive Axle > Page 5602
6. Using the J 8614-01 - tool to hold the pinion nut, remove the pinion nut and the washer.
Note: Use a container in order to retrieve the lubricant.
7. Using the J 8614-01 - tool (1) to hold the pinion yoke, remove the pinion yoke by turning the J
8614-3 (3) clockwise.
Note: Do not damage the housing.
8. Using a suitable tool, remove the pinion oil seal.
Installation Procedure
1. Using the J 33782 - installer for the 8.0 inch, install the pinion seal. 2. Apply sealant to the
splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers (See:
Specifications/Fluid Type
Specifications).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential >
System Information > Service and Repair > Front Drive Axle > Page 5603
3. Align the reference marks and install the pinion yoke.
Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be
damaged if the pinion flange/yoke is hammered onto the pinion shaft.
4. Using a soft-faced hammer, tap the pinion yoke until the threads on the pinion shaft can be seen.
5. Install the washer and a NEW pinion nut.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. While holding the J 8614-01 - tool , tighten the NEW pinion nut in small increments until the end
play is just taken up.
Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible
spacer installed.
Note: Compare this measurement with the rotating torque recorded during removal.
7. Using an inch pound torque wrench, measure the rotating torque of the pinion0.40-0.57 Nm (3-5
lb in) greater than the rotating torque
recorded during removal..
8. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings
have seated. Recheck the rotating torque and adjust if
necessary.
9. Install the propeller shaft.
* For vehicles equipped with one piece propeller shafts, refer to One-Piece Propeller Shaft
Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and
Repair/One-Piece Propeller Shaft Replacement).
* For vehicles equipped with two piece propeller shafts, refer to Two-Piece Propeller Shaft
Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and
Repair/Two-Piece Propeller Shaft Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential >
System Information > Service and Repair > Front Drive Axle > Page 5604
10. Install the rear brake rotors. Refer to Brake Drum Replacement (See: Brakes and Traction
Control/Drum Brake System/Brake Drum/Service and
Repair/Removal and Replacement).
11. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant
Replacement (8.0 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant
Replacement (8.0 Inch Axle))Rear Axle Lubricant Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant
Replacement (8.6 Inch Axle)).
12. Remove the support and lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing >
Component Information > Service and Repair > Front Drive Axle
Axle Bearing: Service and Repair Front Drive Axle
Front Drive Axle Seal and Bearing Replacement
Tools Required
* J 2619-01 Slide Hammer
* J 8092 Universal Drive Handle 3/4 Inch - 10
* J 21426 Extension Housing Seal Installer
* J 29369-2 Bushing and Bearing Remover 2-3 inch
* J 45232 Differential Bearing Adjuster Needle Bearing Installer - Left
Removal Procedure
1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Axle Shaft
Assembly/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing >
Component Information > Service and Repair > Front Drive Axle > Page 5610
2. Remove the swaybar link from the lower control arm. Refer to Stabilizer Shaft Link Replacement
(ZQ8, Z85) (See: Steering and
Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front
Suspension/Stabilizer Shaft Link Replacement (ZQ8, Z85) )Stabilizer Shaft Link Replacement
(Z71) (See: Steering and Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and
Repair/Front Suspension/Stabilizer Shaft Link Replacement (Z71)).
3. Using the J 29369-2 (2) and the J 2619-01 (1) , remove the axle seal.
4. Using the J 29369-2 (1) and the J 2619-01 (2) , remove the axle bearing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing >
Component Information > Service and Repair > Front Drive Axle > Page 5611
1. Position the axle bearing in the intermediate housing. 2. Using the J 45232 (1) and the J 8092
(2) , install the axle bearing.
3. Using the J 21426 (1) , install the axle seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing >
Component Information > Service and Repair > Front Drive Axle > Page 5612
4. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Axle Shaft
Assembly/Service and Repair).
5. Install the swaybar link to the lower control arm. Refer to Stabilizer Shaft Link Replacement
(ZQ8, Z85) (See: Steering and
Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front
Suspension/Stabilizer Shaft Link Replacement (ZQ8, Z85) )Stabilizer Shaft Link Replacement
(Z71) (See: Steering and Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and
Repair/Front Suspension/Stabilizer Shaft Link Replacement (Z71)).
6. Check in fluid level. Refer to Front Axle Lubricant Level Inspection (See: Differential
Assembly/Fluid - Differential/Service and
Repair/Procedures/Front Drive Axle).
7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing >
Component Information > Service and Repair > Front Drive Axle > Page 5613
Axle Bearing: Service and Repair Rear Drive Axle
Rear Axle Shaft Seal and/or Bearing Replacement
Tools Required
* J 8092 Universal Driver Handle- 3/4 in - 10
* J 21128 Axle Pinion Oil Seal Installer
* J 23690 Bearing Installer
* J 2619-01 Slide Hammer
* J 44685 Rear Axle Seal and Bearing Remover
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel
Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair
).
3. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Axle Shaft Assembly/Axle
Shaft/Service and Repair). 4. Using the J 44685 and the J 2619-01 , remove the axle shaft bearing
and seal.
Installation Procedure
1. Using the J 23690 and the J 8092 , install the axle bearing. 2. Using the J 21128 , install the axle
shaft seal. 3. Install the axle shaft. Refer to Rear Axle Shaft Replacement (See: Axle Shaft
Assembly/Axle Shaft/Service and Repair). 4. Install the tire and wheel assembly. Refer to Tire and
Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 5. Fill
the rear axle with axle lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement
(8.0 Inch Axle) (See: Differential
Assembly/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear
Axle Lubricant Replacement (8.0 Inch Axle) )Rear Axle Lubricant Replacement (8.6 Inch Axle)
(See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement/Rear
Drive Axle/Rear Axle Lubricant Replacement (8.6 Inch Axle)).
6. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Axle Shaft > Component Information > Service and Repair
Axle Shaft: Service and Repair
Rear Axle Shaft Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction
Control/Service Precautions/Technician Safety Information/Brake Dust Warning ).
1. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair).
2. Remove the clip retaining the rear brake drum, if required.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Axle Shaft > Component Information > Service and Repair > Page 5618
3. Remove the rear brake drums from the vehicle. 4. Remove the rear axle housing cover.
5. Remove the lock pin bolt.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Axle Shaft > Component Information > Service and Repair > Page 5619
6. Remove the pinion shaft.
7. Remove the C-lock from the rear axle.
8. Remove the rear axle shaft.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Axle Shaft > Component Information > Service and Repair > Page 5620
1. Install the rear axle shaft.
2. Install the C-lock to the rear axle.
3. Install the pinion shaft.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Axle Shaft > Component Information > Service and Repair > Page 5621
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the lock bolt and tighten to 25 Nm (18 lb ft).
5. Install the rear brake drums from the vehicle. 6. Install the rear axle housing cover and gasket.
Refer to Rear Axle Housing Cover and Gasket Replacement (See: Differential
Assembly/Differential Cover/Service and Repair).
7. Fill the rear axle with fluid. Refer to Rear Axle Lubricant Replacement (8.0 Inch Axle) (See:
Differential Assembly/Fluid - Differential/Service
and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.0 Inch
Axle))Rear Axle Lubricant Replacement (8.6 Inch Axle) (See: Differential Assembly/Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant
Replacement (8.6 Inch Axle)).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Axle Shaft > Component Information > Service and Repair > Page 5622
8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement
Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement
Wheel Drive Shaft Inner Joint and Boot Replacement
Special Tools
* J 35910 Drive Axle Seal Clamp Plier
* J 8059 Snap Ring Pliers
Removal Procedure
Note: Before placing the driveshaft in a vise, place protective covers over the vise jaws.
1. Place the driveshaft in a vise.
Note: Do not damage the D/O joint housing while using the hand grinder.
2. Use a hand grinder to cut through the large retaining clamp (2) located at the D/O joint (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 5627
Discard the large retaining clamp.
3. Use a hand grinder to cut through the small retaining clamp (4) on the small end of the seal (3).
Discard the small retaining clamp.
4. Slide the seal (2) down the driveshaft bar and away from the D/O joint (1).
5. Remove the D/O joint housing in the following manner: 6. Collapse and remove the D/O ball
retaining ring using a common hand tool (screwdriver). 7. Pull the D/O joint housing from the
driveshaft bar.
8. Using J 8059 , spread the small retaining ring (1) located in the cage and inner race assembly
(3).
9. Remove the cage and the inner race assembly (1) from the driveshaft bar (2).
10. Remove the balls. 11. Remove the inner race from the cage. 12. Thoroughly degrease all parts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 5628
13. Remove the seal and discard. 14. Clean the driveshaft bar, Use a wire brush to remove any
rust in the seal mounting areas (grooves).
Check the D/O joint housing for unusual wear, cracks, or other damage. Replace the assembly if
any damaged parts are evident.
Installation Procedure
1. Install the new small retaining clamp (2) onto the neck of the seal (1). 2. Slide the small retaining
clamp and seal to their proper position on the driveshaft bar (3).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Secure the small retaining clamp using J 35910 (or equivalent), a breaker bar, and a torque
wrench.
Tighten the small retaining clamp (2) to 136 Nm (100 lb ft).
Note: The cage (3) is NOT symmetrical; the larger outside diameter is the bottom of the cage.
4. Place the cage on the table large diameter side up. 5. Place the inner race (2) with retaining ring
side up into the cage. 6. Place the six balls (1) in the cage windows. 7. Slide the cage/inner race
assembly, small cage diameter first, onto the driveshaft bar.
8. Install the small retaining ring (1) using J 8059 into the groove of the driveshaft bar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 5629
9. Pack the seal and D/O joint housing with the grease suppled in the kit. The amount of grease
supplied in this kit has been pre-measured for this
application.
10. Place the new large retaining clamp on the seal. 11. Slide the D/O joint housing over the cage
and inner race assembly.
12. Insert the D/O ball retaining ring into the groove at the top of the D/O joint housing.
13. Install the seal onto the D/O joint housing.
14. Check the inboard stroke position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 5630
15. Secure the new large retaining clamp and the seal to the D/O joint housing using J 35910 (or
equivalent), a breaker bar, and a torque wrench.
Tighten the large retaining clamp to 176 Nm (130 lb ft).
16. Fully stroke the D/O joint several times to disperse the grease.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 5631
Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement
Wheel Drive Shaft Outer Joint and Boot Replacement
Special Tools
* J 35910 Drive Axle Seal Clamp Plier
* J 8059 Snap Ring Pliers
Removal Procedure
Note: When replacing the outer seal you MUST replace the inner seal.
1. Remove the inner seal. Refer to Wheel Drive Shaft Inner Joint and Boot Replacement (See:
Wheel Drive Shaft Inner Joint and Boot Replacement
).
Note: Do not damage the outer race while using the hand grinder.
2. Use a hand grinder to cut through the large retaining clamp (3) located at the C/V joint (4).
Discard the large retaining clamp.
3. Use a hand grinder to cut through the small retaining clamp (1) on the small end of the outer seal
(2).
Discard the small retaining clamp.
Note: Do NOT remove the C/V joint from the driveshaft bar. If the C/V joint is removed from the
driveshaft bar you must replace the whole driveshaft assembly.
4. Remove the outer seal (1) from the C/V joint (2).
Slide the outer seal (1) away from the C/V joint (2) and remove from the driveshaft bar. Discard the
outer seal.
5. Clean the old grease out of the C/V joint and allow to thoroughly dry.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 5632
1. Pack the C/V joint assembly with the grease supplied in the kit. The amount of grease supplied
in this kit has been pre-measured for this
application.
2. Place the new small retaining clamp onto the outer seal. 3. Place the new large retaining clamp
on the outer seal. 4. Position the small end of the outer seal into the C/V joint outer seal groove on
the driveshaft bar.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Secure the small retaining clamp to the outer seal with J 35910 (or equivalent), a breaker bar,
and a torque wrench.
Tighten the small retaining clamp to 136 Nm (100 lb ft).
6. Slide the large diameter of the outer seal (1), with the large retaining ring (2) in place, over the
outside edge of the C/V joint (3). 7. Position the lip of the outer seal (1) into the groove on the C/V
joint (3). 8. Manipulate the outer seal (1) to remove any excess air.
9. Secure the large retaining clamp to the C/V joint housing with J 35910 (or equivalent), a breaker
bar, and a torque wrench.
Tighten the large retaining clamp to 176 Nm (130 lb ft).
10. Check the gap dimension on the clamp ear. 11. Angulate the C/V joint several times to disperse
the grease. 12. Install the inner seal. Refer to Wheel Drive Shaft Inner Joint and Boot Replacement
(See: Wheel Drive Shaft Inner Joint and Boot Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement
Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Inner Joint and Boot
Replacement
Wheel Drive Shaft Inner Joint and Boot Replacement
Special Tools
* J 35910 Drive Axle Seal Clamp Plier
* J 8059 Snap Ring Pliers
Removal Procedure
Note: Before placing the driveshaft in a vise, place protective covers over the vise jaws.
1. Place the driveshaft in a vise.
Note: Do not damage the D/O joint housing while using the hand grinder.
2. Use a hand grinder to cut through the large retaining clamp (2) located at the D/O joint (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 5637
Discard the large retaining clamp.
3. Use a hand grinder to cut through the small retaining clamp (4) on the small end of the seal (3).
Discard the small retaining clamp.
4. Slide the seal (2) down the driveshaft bar and away from the D/O joint (1).
5. Remove the D/O joint housing in the following manner: 6. Collapse and remove the D/O ball
retaining ring using a common hand tool (screwdriver). 7. Pull the D/O joint housing from the
driveshaft bar.
8. Using J 8059 , spread the small retaining ring (1) located in the cage and inner race assembly
(3).
9. Remove the cage and the inner race assembly (1) from the driveshaft bar (2).
10. Remove the balls. 11. Remove the inner race from the cage. 12. Thoroughly degrease all parts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 5638
13. Remove the seal and discard. 14. Clean the driveshaft bar, Use a wire brush to remove any
rust in the seal mounting areas (grooves).
Check the D/O joint housing for unusual wear, cracks, or other damage. Replace the assembly if
any damaged parts are evident.
Installation Procedure
1. Install the new small retaining clamp (2) onto the neck of the seal (1). 2. Slide the small retaining
clamp and seal to their proper position on the driveshaft bar (3).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Secure the small retaining clamp using J 35910 (or equivalent), a breaker bar, and a torque
wrench.
Tighten the small retaining clamp (2) to 136 Nm (100 lb ft).
Note: The cage (3) is NOT symmetrical; the larger outside diameter is the bottom of the cage.
4. Place the cage on the table large diameter side up. 5. Place the inner race (2) with retaining ring
side up into the cage. 6. Place the six balls (1) in the cage windows. 7. Slide the cage/inner race
assembly, small cage diameter first, onto the driveshaft bar.
8. Install the small retaining ring (1) using J 8059 into the groove of the driveshaft bar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 5639
9. Pack the seal and D/O joint housing with the grease suppled in the kit. The amount of grease
supplied in this kit has been pre-measured for this
application.
10. Place the new large retaining clamp on the seal. 11. Slide the D/O joint housing over the cage
and inner race assembly.
12. Insert the D/O ball retaining ring into the groove at the top of the D/O joint housing.
13. Install the seal onto the D/O joint housing.
14. Check the inboard stroke position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 5640
15. Secure the new large retaining clamp and the seal to the D/O joint housing using J 35910 (or
equivalent), a breaker bar, and a torque wrench.
Tighten the large retaining clamp to 176 Nm (130 lb ft).
16. Fully stroke the D/O joint several times to disperse the grease.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 5641
Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Outer Joint and Boot
Replacement
Wheel Drive Shaft Outer Joint and Boot Replacement
Special Tools
* J 35910 Drive Axle Seal Clamp Plier
* J 8059 Snap Ring Pliers
Removal Procedure
Note: When replacing the outer seal you MUST replace the inner seal.
1. Remove the inner seal. Refer to Wheel Drive Shaft Inner Joint and Boot Replacement (See:
Constant Velocity Joint/Service and Repair/Wheel
Drive Shaft Inner Joint and Boot Replacement).
Note: Do not damage the outer race while using the hand grinder.
2. Use a hand grinder to cut through the large retaining clamp (3) located at the C/V joint (4).
Discard the large retaining clamp.
3. Use a hand grinder to cut through the small retaining clamp (1) on the small end of the outer seal
(2).
Discard the small retaining clamp.
Note: Do NOT remove the C/V joint from the driveshaft bar. If the C/V joint is removed from the
driveshaft bar you must replace the whole driveshaft assembly.
4. Remove the outer seal (1) from the C/V joint (2).
Slide the outer seal (1) away from the C/V joint (2) and remove from the driveshaft bar. Discard the
outer seal.
5. Clean the old grease out of the C/V joint and allow to thoroughly dry.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 5642
1. Pack the C/V joint assembly with the grease supplied in the kit. The amount of grease supplied
in this kit has been pre-measured for this
application.
2. Place the new small retaining clamp onto the outer seal. 3. Place the new large retaining clamp
on the outer seal. 4. Position the small end of the outer seal into the C/V joint outer seal groove on
the driveshaft bar.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Secure the small retaining clamp to the outer seal with J 35910 (or equivalent), a breaker bar,
and a torque wrench.
Tighten the small retaining clamp to 136 Nm (100 lb ft).
6. Slide the large diameter of the outer seal (1), with the large retaining ring (2) in place, over the
outside edge of the C/V joint (3). 7. Position the lip of the outer seal (1) into the groove on the C/V
joint (3). 8. Manipulate the outer seal (1) to remove any excess air.
9. Secure the large retaining clamp to the C/V joint housing with J 35910 (or equivalent), a breaker
bar, and a torque wrench.
Tighten the large retaining clamp to 176 Nm (130 lb ft).
10. Check the gap dimension on the clamp ear. 11. Angulate the C/V joint several times to disperse
the grease. 12. Install the inner seal. Refer to Wheel Drive Shaft Inner Joint and Boot Replacement
(See: Constant Velocity Joint/Service and Repair/Wheel
Drive Shaft Inner Joint and Boot Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair
Seals and Gaskets: Service and Repair
Front Drive Axle Seal and Bearing Replacement
Tools Required
* J 2619-01 Slide Hammer
* J 8092 Universal Drive Handle 3/4 Inch - 10
* J 21426 Extension Housing Seal Installer
* J 29369-2 Bushing and Bearing Remover 2-3 inch
* J 45232 Differential Bearing Adjuster Needle Bearing Installer - Left
Removal Procedure
1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Axle Shaft
Assembly/Service and Repair).
2. Remove the swaybar link from the lower control arm. Refer to Stabilizer Shaft Link Replacement
(ZQ8, Z85) (See: Steering and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Page 5646
Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front
Suspension/Stabilizer Shaft Link Replacement (ZQ8, Z85) )Stabilizer Shaft Link Replacement
(Z71) (See: Steering and Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and
Repair/Front Suspension/Stabilizer Shaft Link Replacement (Z71)).
3. Using the J 29369-2 (2) and the J 2619-01 (1) , remove the axle seal.
4. Using the J 29369-2 (1) and the J 2619-01 (2) , remove the axle bearing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Page 5647
1. Position the axle bearing in the intermediate housing. 2. Using the J 45232 (1) and the J 8092
(2) , install the axle bearing.
3. Using the J 21426 (1) , install the axle seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Page 5648
4. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Axle Shaft
Assembly/Service and Repair).
5. Install the swaybar link to the lower control arm. Refer to Stabilizer Shaft Link Replacement
(ZQ8, Z85) (See: Steering and
Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front
Suspension/Stabilizer Shaft Link Replacement (ZQ8, Z85) )Stabilizer Shaft Link Replacement
(Z71) (See: Steering and Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and
Repair/Front Suspension/Stabilizer Shaft Link Replacement (Z71)).
6. Check in fluid level. Refer to Front Axle Lubricant Level Inspection (See: Differential
Assembly/Fluid - Differential/Service and
Repair/Procedures/Front Drive Axle).
7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Testing and Inspection
Wheel Bearing: Testing and Inspection
Wheel Bearings Diagnosis
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Testing and Inspection > Page 5652
Wheel Bearing: Service and Repair
Front Wheel Bearing and Hub Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction
Control/Service Precautions/Technician Safety Information/Brake Dust Warning ).
Warning: Refer to ABS Component Handling Warning (See: Brakes and Traction Control/Service
Precautions/Technician Safety Information/ABS Component Handling Warning).
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Remove the front brake caliper. Refer to Brake Caliper Replacement
(See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Brake Caliper Replacement).
3. Remove the speed sensor electrical connector and the mounting bracket. Refer to Front Wheel
Speed Sensor Replacement (See: Brakes and
Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and
Repair/Front Wheel Speed Sensor Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Testing and Inspection > Page 5653
4. To ensure the ease of removal, bundle speed sensor wiring harness so not to have it entangled
in any of the suspension components.
Note: The following service procedure applies to those vehicles that are equipped with 4 wheel
drive ONLY.
5. Remove the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Steering
and Suspension/Steering/Front Steering
Knuckle/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Testing and Inspection > Page 5654
6. Remove the mounting bolts for the wheel bearing/hub, brake rotor assembly.
7. Remove the wheel bearing/hub, brake rotor assembly from the steering knuckle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Testing and Inspection > Page 5655
Note: Perform the following service procedure with the brake rotor on a flat surface.
8. Remove the mounting bolt from the wheel bearing/hub, to the brake rotor.
Note: The splash shield will come off the steering knuckle when the wheel bearing/hub, brake rotor
is removed.
9. Remove the wheel bearing/hub from the brake rotor.
10. Clean the contact area between the wheel bearing/hub and the brake rotor.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Testing and Inspection > Page 5656
1. Position the wheel bearing/hub assembly on the brake rotor. 2. Install the mounting bolts from
the wheel bearing/hub assembly to the brake rotor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: The following service procedure is to be performed on a flat surface and to ensure that the
brake rotor is securely attached to the hub assembly prior to the final torquing procedure. DO NOT
use air tools of any type for this procedure.
3. Tighten the bolts in crisscross pattern. Tighten the mounting bolts to 20 Nm (15 lb ft). 4. Install
the backing plate to the wheel bearing/hub, brake rotor assembly.
Note: The following service procedure applies to those vehicles that are equipped with 4 wheel
drive ONLY.
5. Install the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Steering
and Suspension/Steering/Front Steering
Knuckle/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Testing and Inspection > Page 5657
6. Install the wheel bearing/hub, brake rotor assembly in the steering knuckle.
Note: When performing the following service procedure, DO NOT use air tools of any type to torque
the brake rotor to hub bolts.
7. Install the wheel bearing/hub, brake rotor mounting bolts and tighten to 125 Nm (92 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Testing and Inspection > Page 5658
8. Install the brake caliper mounting bracket to the steering knuckle.
9. Install the mounting bolts for the brake caliper mounting bracket and tighten to 175 Nm (129 lb
ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Testing and Inspection > Page 5659
10. Position a large screwdriver or pry bar in the cooling fins of the brake rotor and the brake
caliper mounting bracket.
Note: The following service procedure is to ensure that the brake rotor is seated properly on the
wheel bearing/hub assembly.
11. Tighten the mounting bolts for the brake rotor in sequence.
12. Using a torque wrench, tighten the mounting bolts to 110 Nm (81 lb ft). 13. Install the speed
sensor mounting bracket and re-connect the electrical connector. Refer to Front Wheel Speed
Sensor Replacement (See: Brakes
and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and
Repair/Front Wheel Speed Sensor Replacement).
14. Check for hub/rotor/bearing LRO specifications. Refer to Disc Brake Component Specifications
(See: Brakes and Traction Control/Disc Brake
System/Specifications/Disc Brake Component Specifications).
15. Install the brake caliper assembly. Refer to Brake Caliper Replacement (See: Brakes and
Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Brake Caliper Replacement).
16. Install the wheel speed sensor to the body. 17. Lower the vehicle. Refer to Lifting and Jacking
the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Specifications
Axle Nut: Specifications
Drive Shaft Nut ....................................................................................................................................
.................................................... 260 Nm (191 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support
> Component Information > Service and Repair
Center Support: Service and Repair
Propeller Shaft Center Support Bearing Replacement
Special Tools
* J 37372 Bearing Installer
* J 44749 Split Plate
Removal Procedure
1. Remove the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement (See:
Drive/Propeller Shaft/Service and Repair/Two-Piece
Propeller Shaft Replacement).
2. Mark the relationship of the yoke to the driveshaft.
3. Mark the relationship of the U-Joint to the yoke. 4. Remove the U-Joint from the yoke.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support
> Component Information > Service and Repair > Page 5668
Note: The following service is to protect the machined portion of the slip yoke.
5. Using 2 or 3 clean shop towels, wrap the slip yoke with the towels and secure with electrical ties
or electrical tape.
6. Remove the retaining nut for the yoke.
7. Remove the washer from the yoke.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support
> Component Information > Service and Repair > Page 5669
8. Remove the yoke from the propeller shaft.
Note: When installing the special tool, the aid of an assistant will be required to position the tool
between the center bearing and propeller shaft shoulder. Ensure that the flat part of the tool is
facing center bearing.
9. Install the J 44749 (1) to the propeller shaft.
1. With the aid of an assistant, pull the center bearing toward the spline part of the propeller shaft.
2. Position the tool (1) between the center bearing and the shield for the center bearing. 3. Adjust
the tool so that it just comes in contact with the shoulder.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support
> Component Information > Service and Repair > Page 5670
Note: It will be necessary to adjust the hydraulic press so that the slip yoke does not touch the
ground.
10. Install the propeller shaft in a hydraulic press. 11. Position a piece of wood between the floor
and the slip yoke. 12. Remove the center bearing (1) from the propeller shaft. 13. Remove the tool
from the propeller shaft.
Installation Procedure
1. Position the center bearing on the propeller shaft.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support
> Component Information > Service and Repair > Page 5671
2. Install the J 37372 on the propeller shaft.
3. Using the J 37372 (1), install the center bearing on the propeller shaft.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support
> Component Information > Service and Repair > Page 5672
Note: Failure to align the reference marks properly will cause a vibration the propeller shaft.
4. Position the yoke on the propeller shaft so that the reference marks are aligned properly. 5.
Using a brass or hard rubber hammer, lightly tap the yoke on the propeller shaft. 6. Install the
washer.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: Tighten the retaining nut by hand before tightening the retaining nut to the proper
specifications.
7. Install the retaining nut and tighten to 167 Nm (123 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support
> Component Information > Service and Repair > Page 5673
8. Align the U-Joint to the reference marks on the propeller shaft and yoke. 9. Install the U-Joint to
the yoke.
10. Remove the shop towels from the propeller shaft. 11. Install the propeller shaft in the vehicle.
Refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shaft/Service and
Repair/Two-Piece Propeller Shaft Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Specifications > Mechanical Specifications
Drive/Propeller Shaft: Mechanical Specifications
Fastener Tightening Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Specifications > Mechanical Specifications > Page 5678
Drive/Propeller Shaft: Fluid Type Specifications
Adhesives, Fluids, Lubricants, and Sealers
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Specifications > Page 5679
Drive/Propeller Shaft: Diagrams
Driveline Disassembled Views
Front Drive Propeller Shaft
1 - Universal Joint Spider Assembly 2 - Propeller Shaft Tube Assembly
One-Piece Propeller Shaft
1 - Propeller Shaft Slip Yoke 2 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 3 Propeller Shaft Universal Joint 4 - Propeller Shaft Tube 5 - Propeller Shaft Universal Joint Spider
Bearing Retainer Ring 6 - Propeller Shaft Universal Joint 7 - Propeller Shaft Bearing Retainer 8 Propeller Shaft Bearing Retainer Bolt
Two-Piece Propeller Shaft
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Specifications > Page 5680
1 - Propeller Shaft Slip Yoke 2 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 3 Propeller Shaft Universal Joint and Bearing 4 - Propeller Shaft Tube 5 - Propeller Shaft Center
Bearing 6 - Propeller Shaft Yoke 7 - Propeller Shaft Yoke Retaining Nut 8 - Propeller Shaft
Universal Joint and Bearing 9 - Propeller Shaft Universal Joint Bearing Retaining Ring 10 Propeller Shaft Tube 11 - Propeller Shaft Universal Joint and Bearing 12 - Propeller Shaft Universal
Joint Bearing Retaining Ring
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Specifications > Page 5681
Drive/Propeller Shaft: Description and Operation
Propeller Shaft Description and Operation
The propeller shaft is a tube with universal joints at both ends which do not require periodic
maintenance, that transmit power from the transfer case or transmission output shaft to the
differential.
Front Propeller Shaft Description
The front propeller shaft transmits rotating force from the transfer case to the front differential when
the transfer case is engaged. The front propeller shaft connects to the transfer case using a splined
slip joint.
One Piece Propeller Shaft Description
A 1 piece propeller shaft uses a splined slip joint to connect the driveline to the transmission or
transfer case.
Two Piece Propeller Shaft Description
There are 3 universal joints used on the two piece propeller shaft, A center bearing assembly is
used to support the propeller shaft connection point, and help isolate the vehicle from vibration.
Propeller Shaft Phasing Description
The propeller shaft is designed and built with the yoke lugs (ears) in line with each other. This
produces the smoothest running shaft possible. A propeller shaft designed with built in yoke lugs in
line is known as in - phase. An out of phase propeller shaft often causes vibration. The propeller
shaft generates vibration from speeding up and slowing down each time the universal joint goes
around. The vibration is the same as a person snapping a rope and watching the wave reaction
flow to the end. An in phase propeller shaft is similar to 2 persons snapping a rope at the same
time and watching the waves meet and cancel each other out. A total cancellation of vibration
produces a smooth flow of power in the drive line. All splined shaft slip yokes are keyed in order to
ensure proper phasing.
Universal Joint Description
The universal joint is connected to the propeller shaft. The universal consist of 4 caps with needle
bearings and grease seals mounted on the trunnions of a cross or spider. These bearings and caps
are greased at the factory and no periodic maintenance is required. There are 2 universal joints
used in a one piece propeller shaft and 3 used in two piece propeller shaft. The bearings and caps
are pressed into the yokes and held in place with snap rings, except for 2 bearings on some
models witch are strapped onto the pinion flange of the differential. Universal joints are designed to
handle the effects of various loads and rear axle windup conditions during acceleration and
braking. The universal joint operates efficiently and safely within the designed angle variations.
when the design angles are exceeded, the operational life of the joint decreases.
Center Bearing Description
Center bearings support the driveline when using 2 or more propeller shafts. The center bearing is
a ball bearing mounted in a rubber cushion that attaches to a frame crossmember. The
manufacturer prelubricates and seals the bearing. The cushion allows vertical motion at the
driveline and helps isolate the vehicle from vibration.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Drive/Propeller Shaft: Initial Inspection and Diagnostic Overview
Diagnostic Starting Point - Propeller Shaft
Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the
Description and Operation information will help you determine the correct symptom diagnostic
procedure when a malfunction exists. Reviewing the Description and Operation information will
also help you determine if the condition described by the customer is normal operation. Refer to
Symptoms - Propeller Shaft (See: Symptom Related Diagnostic Procedures/Symptoms - Propeller
Shaft) in order to identify the correct procedure for diagnosing the system and where the procedure
is located.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5684
Drive/Propeller Shaft: Symptom Related Diagnostic Procedures
Symptoms - Propeller Shaft
Symptoms - Propeller Shaft
Before beginning diagnosis, review the system description and operation in order to familiarize
yourself with the system function. Refer to Propeller Shaft Description and Operation (See:
Description and Operation).
Classifying the Symptom
Propeller Shaft symptoms can usually be classified into the following categories:
* Leaks
* Noises
* Vibrations
Leak and noise related symptoms are diagnosed within the Propeller Shaft section. For vibration
related symptoms, refer to Diagnostic Starting Point - Vibration Diagnosis and Correction (See:
Testing and Inspection/Symptom Related Diagnostic Procedures/Vibration Diagnosis and
Correction/Diagnostic Information and Procedures/Diagnostic Starting Point - Vibration Diagnosis
and Correction).
Visual/Physical Inspection
* Inspect the system for aftermarket devices which could affect the operation of the Propeller Shaft.
* Inspect the easily accessible or visible system components for obvious damage or conditions
which could cause the symptom.
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
* Leak at Front Slip Yoke (See: Leak at Front Slip Yoke)
* Universal Joint Noise (See: Universal Joint Noise)
* Ping, Snap, or Click Noise (See: Ping, Snap, or Click Noise)
* Knock or Clunk Noise (See: Knock or Clunk Noise)
* Scraping Noise (See: Scraping Noise)
* Squeak Noise (See: Squeak Noise)
* Shudder on Acceleration at Low Speed (See: Shudder on Acceleration at Low Speed)
Knock or Clunk Noise
Knock or Clunk Noise
Leak at Front Slip Yoke
Leak at Front Slip Yoke
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5685
Ping, Snap, or Click Noise
Ping, Snap, or Click Noise
Scraping Noise
Scraping Noise
Shudder on Acceleration at Low Speed
Shudder on Acceleration at Low Speed
Squeak Noise
Squeak Noise
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5686
Universal Joint Noise
Universal Joint Noise
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement
Drive/Propeller Shaft: Service and Repair Front Propeller Shaft Replacement
Front Propeller Shaft Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Mark the front U-joint to the pinion yoke on the
front differential.
3. Mark the relationship of the rear U-joint to the transfer case drive flange. 4. Mark the relationship
of the rear U-joint to the transfer case drive flange.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5689
5. Remove the retaining nuts and bolts from the drive flange.
6. Remove the clamps and retaining bolts from the front drive axle pinion flange.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5690
7. Remove the front propeller shaft from the vehicle. 8. Using tape and or a rubber band, wrap the
front U-joint bearing caps to ensure the caps do not separate from the U-joint.
Installation Procedure.
1. Remove the tape or rubber band from the front U-joint 2. Install the front propeller shaft.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5691
3. Align the reference marks on the front U-joint.
Note: When installing the retaining bolts, only tighten them finger tight to hold the front propeller
shaft in position.
4. Install the front U-joint bolts and clamps.
5. Align the reference marks on the rear U-joint.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5692
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the propeller shaft to pinion flange bolts.
* Tighten the bolts from the propeller shaft to the pinion flange 20 Nm (15 lbft).
* Tighten the bolts for the front propeller U-joint clamps 20 Nm (15 lb ft).
7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5693
Drive/Propeller Shaft: Service and Repair One-Piece Propeller Shaft Replacement
One-Piece Propeller Shaft Replacement
Removal Procedure
1. Place the transmission in neutral. 2. Release the park brake, if applied. 3. Raise and support the
vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and
Repair). 4. Mark the rear universal joint to the drive shaft flange.
5. Remove the retaining bolts and clamps. 6. Remove the propeller shaft from the pinion drive
flange.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5694
7. Remove the propeller shaft from the transmission/transfer case.
8. Using tape or a rubber band, wrap the U-Joint bearing caps to ensure the bearing caps do not
separate from the U-Joint.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5695
1. Remove the tape or rubber band from the U-Joint.
2. Install the propeller shaft in the transmission/transfer case.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5696
3. Align the propeller shaft with the reference marks on the pinion flange.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the clamps and retaining bolts and tighten the bolts to 20 Nm (15 lb ft). 5. Lower the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5697
Drive/Propeller Shaft: Service and Repair Two-Piece Propeller Shaft Replacement
Two-Piece Propeller Shaft Replacement
Removal Procedure
Caution: Refer to Propeller Shaft Caution (See: Service Precautions).
1. Place transmission in neutral. 2. Release the park brake, if applied. 3. Raise and support the
vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and
Repair).
Note: The following service procedure will ensure the proper alignment of all U-Joint to the
transmission, center bearing support and the rear drive axle pinion flange.
4. Rotate the propeller shafts so that all the external clips are aligned. 5. Mark the rear propeller
shaft to the pinion drive flange, center bearing support, and transmission.
6. Remove the clamps and retaining bolts for the rear propeller shaft at the pinion drive flange and
the center bearing. 7. Using tape or a rubber band, wrap the rear U-Joint bearing caps to ensure
that they not separate from the U-Joint. 8. Remove the rear propeller shaft from the center bearing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5698
9. Remove the mounting bolts for the center bearing.
10. Remove the center bearing from the crossmember. 11. Remove the propeller shaft from the
transmission.
Installation Procedure
1. Align the reference marks on the propeller shaft to the transmission. 2. Install the propeller shaft
in the transmission. 3. Install the center bearing to the crossmember.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the center bearing mounting bolts and tighten to 80 Nm (59 lb ft). 5. Rotate the propeller
shaft so that the alignment marks and the pinion yoke are in alignment. 6. Remove the tape and or
rubber band.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5699
7. Position the U-Joint in the pinion yoke. 8. Install the clamps and retaining bolts and tighten the
bolts to 30 Nm (22 lb ft). 9. Double check the alignment marks to ensure that they are aligned
properly
10. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Page 5700
Drive/Propeller Shaft: Tools and Equipment
Special Tools
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair
Universal Joint: Service and Repair
Universal Joint Replacement - External Snap Ring
Special Tools
* J 9522-3 U-Joint Bearing Separator
* J 9522-5 U-Joint Bearing Spacer Remover
Disassembly Procedure
Caution: Never clamp propeller shaft tubing in a vise. Clamping propeller shaft tubing in a vise
could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of
the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks
may damage the bushing or cut the lip seal.
1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller
shaft in order to show which end connects to the transmission and which end goes to the rear axle.
3. Disassemble the snap rings by pinching the ends together with a pair of pliers. 4. If the ring does
not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the
pressure from the ring.
5. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex
head socket or a 27 mm (1-1/16 in) socket.
6. Place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke
ear. 7. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between
the seal and the bearing cup you are removing.
Continue pressing the bearing cup out of the yoke.
8. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 9. Mark the
orientation of the slip yoke to the tube for proper reassembly.
10. Remove the cross from the yoke. 11. Remove the remaining universal joint parts from the yoke.
12. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the
same manner. 13. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 14.
Inspect the bearing cup bores for burrs or imperfections. 15. Clean the retaining ring grooves.
Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing
into place or
prevent the bearing retainers from properly seating.
Assembly Procedure
1. Remove the bearing cups from the universal joint.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Page 5704
2. Assemble one bearing cup part way into 1 side of the yoke. Turn the yoke ear toward the
bottom. 3. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup.
4. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing
cup is flush with the yoke ear. 5. Install the opposite bearing cup part way into the yoke ear. 6.
Ensure that the trunnions start straight and true into both bearing cups. 7. Press the opposite
bearing cup into the yoke ear while working the cross all the time in order to inspect for free
unbinding movement of the
trunnions in the bearing cups.
Note: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for
misalignment in the bearing cup.
8. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of
the bearing cup.
9. Assemble the bearing retainer in the retainer groove.
10. Continue pressing until both retainers can be snapped into place.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Page 5705
11. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a dead
blow hammer. 12. It may be necessary to lubricate the snap ring with a slight amount of chassis
grease so that the snap ring seats in the bearing cup groove.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
FLYWHEEL/FLEXPLATE
Automatic Transmission Flex Plate Bolts First Pass............................................................................
...........................................................................................................................20 Nm (15 lb ft)
Second Pass........................................................................................................................................
...........................................................50 Nm (37 lb ft) Final Pass........................................................
............................................................................................................................................100 Nm
(74 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair >
Engine Flywheel Replacement
Flex Plate: Service and Repair Engine Flywheel Replacement
Engine Flywheel Replacement
Removal Procedure
1. Remove the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See:
Automatic Transmission/Transaxle/Service and
Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal
and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement). Note: Note the position
and direction of the engine flywheel before removal.
2. Remove the engine flywheel bolts. 3. Remove the engine flywheel. 4. Clean and inspect the
engine flywheel. Refer to Automatic Transmission Flex Plate Cleaning and Inspection ().
Installation Procedure
Note: The flywheel does not use a locating pin for alignment and will not initially seat against the
crankshaft flange, but will be pulled onto the crankshaft by the engine flywheel bolts. This
procedure requires a three stage tightening process.
1. Install the engine flywheel to the crankshaft. 2. Apply threadlock to the threads of the flywheel
bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part
number.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair >
Engine Flywheel Replacement > Page 5711
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the engine flywheel bolts.
* Tighten the bolts a first pass in sequence to 20 Nm (15 lb ft).
* Tighten the bolts a second pass in sequence to 50 Nm (37 lb ft).
* Tighten the bolts a final pass in sequence to 100 Nm (74 lb ft).
4. Install the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See:
Automatic Transmission/Transaxle/Service and
Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal
and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair >
Engine Flywheel Replacement > Page 5712
Flex Plate: Service and Repair Automatic Transmission Flex Plate Replacement
Automatic Transmission Flex Plate Replacement
Removal Procedure
1. Remove the automatic transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L)
(See: Automatic Transmission/Transaxle/Service
and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal
and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement) for the 4L60-E.
Important: Note the position and direction of the engine flywheel before removal.
2. Remove the flywheel bolts. 3. Remove the flywheel.
4. Install two M11x1.5 mm bolts (1) to the threaded holes of the spacer, if applicable. 5. Rotate the
bolts clockwise to remove the spacer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair >
Engine Flywheel Replacement > Page 5713
6. Remove the spacer from the rear of the crankshaft, if applicable.
Installation Procedure
Note:
* The flywheel does not use a locating pin for alignment and will not initially seat against the
crankshaft flange or spacer, if applicable, but will be pulled onto the crankshaft by the engine
flywheel bolts. This procedure requires a three stage tightening process.
* Certain applications (6.0L) require a spacer and longer bolts for proper flywheel position.
1. Install the spacer, if applicable, onto the rear of the crankshaft.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair >
Engine Flywheel Replacement > Page 5714
Note: Longer flywheel bolts must be used on applications using a flywheel spacer.
2. Install the flywheel and bolts to the crankshaft. 3. Apply threadlock to the threads of the flywheel
bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part
number.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Tighten the flywheel bolts.
* Tighten the bolts (1-6) a first pass in sequence to 20 Nm (15 lb ft).
* Tighten the bolts (1-6) a second pass in sequence to 50 Nm (37 lb ft).
* Tighten the bolts (1-6) a final pass in sequence to 100 Nm (74 lb ft).
5. Install the automatic transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L)
(See: Automatic Transmission/Transaxle/Service
and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal
and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement) for the 4L60-E.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications
Flywheel: Specifications
FLYWHEEL/FLEXPLATE
Engine Flywheel bolts First pass in sequence to..................................................................................
..............................................................................................20 Nm (15 lb ft) Second pass in
sequence to..........................................................................................................................................
.................................50 Nm (37 lb ft) Final pass in sequence to..........................................................
...................................................................................................................100 Nm (74 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page
5718
Flywheel: Service and Repair
Engine Flywheel Replacement
Removal Procedure
1. Remove the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See:
Automatic Transmission/Transaxle/Service and
Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal
and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement). Note: Note the position
and direction of the engine flywheel before removal.
2. Remove the engine flywheel bolts. 3. Remove the engine flywheel. 4. Clean and inspect the
engine flywheel. Refer to Automatic Transmission Flex Plate Cleaning and Inspection ().
Installation Procedure
Note: The flywheel does not use a locating pin for alignment and will not initially seat against the
crankshaft flange, but will be pulled onto the crankshaft by the engine flywheel bolts. This
procedure requires a three stage tightening process.
1. Install the engine flywheel to the crankshaft. 2. Apply threadlock to the threads of the flywheel
bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part
number.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page
5719
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the engine flywheel bolts.
* Tighten the bolts a first pass in sequence to 20 Nm (15 lb ft).
* Tighten the bolts a second pass in sequence to 50 Nm (37 lb ft).
* Tighten the bolts a final pass in sequence to 100 Nm (74 lb ft).
4. Install the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See:
Automatic Transmission/Transaxle/Service and
Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal
and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Specifications > Capacity Specifications
Fluid - M/T: Capacity Specifications
Manual Transmission Fluid ..................................................................................................................
................................................. 2.2 liters (2.3 quarts)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Specifications > Capacity Specifications > Page 5725
Fluid - M/T: Fluid Type Specifications
MANUAL TRANSMISSION FLUID SAE 75W-90, API AI-A or GL-3 GM Part No. U.S. 89021806, in
Canada 89021807.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Specifications > Page 5726
Fluid - M/T: Service and Repair
Transmission Fluid Replacement
Draining Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Clean away all dirt and debris from the transmission fluid drain plug area. 3. Position an
appropriate container under the transmission. 4. Remove the transmission fluid drain plug and
washer.
Discard the washer. Allow the transmission fluid to drain into the container.
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
5. Install the transmission fluid drain plug and NEW washer.
Tighten the drain plug to 37 Nm (27 lb ft).
6. Remove the container used to catch the used transmission fluid from under the vehicle.
Filling Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Specifications > Page 5727
1. Clean away all dirt and debris from the transmission fluid fill plug area. 2. Remove the
transmission fluid fill plug and washer.
Discard the washer.
3. Fill the transmission to just below the bottom of the fill plug hole with the recommended fluid.
Refer to Lubrication Specifications (See:
Specifications/Fluid Type Specifications).
4. Install the transmission fluid fill plug and NEW washer.
Tighten the fill plug to 37 Nm (27 lb ft).
5. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T >
Component Information > Service and Repair
Input Shaft: Service and Repair
Input Shaft Bearing Retainer Replacement
Removal Procedure
1. Drain the transmission fluid. Refer to Transmission Fluid Replacement (See: Service and
Repair/Removal and Replacement/Transmission Fluid
Replacement).
2. Remove the clutch actuator cylinder. Refer to Clutch Actuator Cylinder Replacement (See:
Clutch/Clutch Hydraulic System/Clutch Slave
Cylinder/Service and Repair).
3. Remove the input shaft bearing retainer bolts.
Discard the bolts.
4. Remove the input shaft bearing retainer. 5. Clean and inspect the input shaft bearing retainer.
Refer to Transmission Case Cleaning and Inspection (See: Service and
Repair/Overhaul/Cleaning and Inspection/Transmission Case Cleaning and Inspection).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T >
Component Information > Service and Repair > Page 5731
1. Apply a 3 mm (1/8 in) bead of sealant GM P/N 89020326 (Canadian P/N 89021188) to the input
shaft bearing retainer.
Note: Ensure the seal does not catch on the input shaft splines.
2. Position the input shaft bearing retainer to the transmission. 3. Apply pipe sealant GM P/N
12346004 (Canadian P/N 10953480) to the threads of the input shaft bearing retainer bolts if new
bolts are not
available.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the NEW input shaft bearing retainer bolts.
Tighten the input shaft bearing retainer bolts to 17 Nm (13 lb ft).
5. Install the clutch actuator cylinder. Refer to Clutch Actuator Cylinder Replacement (See:
Clutch/Clutch Hydraulic System/Clutch Slave
Cylinder/Service and Repair).
6. Fill the transmission fluid. Refer to Transmission Fluid Replacement (See: Service and
Repair/Removal and Replacement/Transmission Fluid
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T >
Component Information > Service and Repair > Page 5732
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T >
System Information > Service and Repair > Transmission Input Shaft Seal Replacement
Seals and Gaskets: Service and Repair Transmission Input Shaft Seal Replacement
Transmission Input Shaft Seal Replacement
Tools Required
J 45866 Input Shaft Seal Installer
Removal Procedure
1. Remove the transmission input shaft bearing retainer. Refer to Input Shaft Bearing Retainer
Replacement (See: Input Shaft/Service and Repair).
2. Using a hammer and a punch, remove the input shaft seal from the input shaft bearing retainer.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T >
System Information > Service and Repair > Transmission Input Shaft Seal Replacement > Page 5737
1. Using the J 45866 and a hammer, install the input shaft seal into the input shaft bearing retainer.
* The spring side of the seal goes toward the tool
* Ensure the seal is installed square
* The tool will install the seal to the correct depth
2. Install the transmission input shaft bearing retainer. Refer to Input Shaft Bearing Retainer
Replacement (See: Input Shaft/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T >
System Information > Service and Repair > Transmission Input Shaft Seal Replacement > Page 5738
Seals and Gaskets: Service and Repair Transmission Housing Oil Seal Replacement - Rear
Transmission Housing Oil Seal Replacement - Rear (RWD)
Tools Required
J 45868 RWD Output Shaft Seal Installer
Removal Procedure
1. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See:
Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or
Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement).
2. Using a suitable tool, pry the rear transmission housing oil seal from the transmission housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T >
System Information > Service and Repair > Transmission Input Shaft Seal Replacement > Page 5739
1. Using the J 45868 and a hammer, install the NEW rear transmission housing oil seal. 2. Check
the transmission fluid level. Add if necessary. Refer to Transmission Fluid Replacement (See:
Service and Repair/Removal and
Replacement/Transmission Fluid Replacement).
3. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See:
Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller
Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft
Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and
Repair/Two-Piece Propeller Shaft Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams
Clutch Pedal Position Sensor / Switch: Diagrams
Component Connector End Views
Clutch Pedal Position (CPP) Sensor (MA5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 5744
Clutch Pedal Position Sensor / Switch: Service and Repair
Clutch Pedal Position Switch Replacement
Removal Procedure
1. Disconnect the electrical connector (2) from the clutch pedal position switch (1).
2. Push the clutch pedal position switch retaining plate locking tabs (2) inward toward each other to
release. 3. Remove the clutch pedal position switch (3) from the clutch pedal assembly (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 5745
1. Slide the clutch pedal position switch (3) with retaining plate (2) into the clutch pedal bracket (1),
until the locking tabs (2) are fully engaged.
2. Connect the electrical connector (2) to the clutch pedal position switch (1). 3. Complete the
following in order to adjust the clutch pedal position switch (1).
1. Push the switch fully into the bracket, allowing the switch to ratchet in the retaining plate. 2.
Depress the clutch pedal all the way to the floor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Service and Repair > Shift Lever Assembly Replacement (w/o D06)
Shifter M/T: Service and Repair Shift Lever Assembly Replacement (w/o D06)
Shift Lever Assembly Replacement (w/o D06)
Removal Procedure
1. Pull upward on the front of the boot (3) in order to disengage the boot retainers (2) from the floor
console (1).
2. Remove the set screw (1) from the shift lever (2). 3. Remove the shift lever assembly from the
control lever.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Service and Repair > Shift Lever Assembly Replacement (w/o D06) > Page 5750
1. Install the shift lever assembly to the control lever, aligning the set screw threaded hole with the
seat (3) 2. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488) to the shift lever set
screw threads.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the shift lever set screw and tighten to 25 Nm (18 lb ft).
4. Position the boot tabs (4) under the rear of the console opening. 5. Push downward on the front
of the boot (3) in order to engage the boot retainers (2) with the floor console (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Service and Repair > Shift Lever Assembly Replacement (w/o D06) > Page 5751
Shifter M/T: Service and Repair Shift Lever Assembly Replacement (D06)
Shift Lever Assembly Replacement (D06)
Removal Procedure
1. Pull upward on the boot (1) in order to disengage the bezel retainers (2) from the console (3).
2. Remove the set screw (1) from the shift lever (2). 3. Remove the shift lever assembly from the
control lever.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Service and Repair > Shift Lever Assembly Replacement (w/o D06) > Page 5752
1. Install the shift lever assembly to the control lever, aligning the set screw threaded hole with the
seat (3). 2. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488) to the shift lever set
screw threads.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the shift lever set screw and tighten to 25 Nm (18 lb ft).
4. Push downward on the bezel in order to engage the bezel retainers (2) with the console (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift
Boot, M/T > Component Information > Service and Repair
Shift Boot: Service and Repair
Control Lever and/or Boot Replacement
Removal Procedure
1. Remove the shift lever assembly. Refer to Shift Lever Assembly Replacement (w/o D06) (See:
Shifter M/T/Service and Repair/Shift Lever
Assembly Replacement (w/o D06))Shift Lever Assembly Replacement (D06) (See: Shifter
M/T/Service and Repair/Shift Lever Assembly Replacement (D06)).
2. Remove the console (w/o D06 only). Refer to Console Replacement (Large w/Manual or Auto
Transmission) (See: Body and Frame/Interior
Moulding / Trim/Console/Service and Repair)Console Replacement (Small w/Manual
Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair).
3. Remove the control lever boot screws. 4. Tilt and remove the control lever boot from the control
lever. 5. Shift the transmission into neutral (N).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift
Boot, M/T > Component Information > Service and Repair > Page 5757
6. Remove the control lever housing assembly bolts. 7. Remove the control lever housing
assembly and gasket. 8. Mask off the control lever housing opening, in order to prevent foreign
objects from entering the transmission. 9. Disassemble the control lever housing if necessary.
Refer to Shift Control Housing Disassemble (See: Service and
Repair/Overhaul/Disassembly/Shift Control Housing Disassemble).
Installation Procedure
1. Assemble the control lever housing if previously disassembled. Refer to Shift Control Housing
Assemble (See: Service and
Repair/Overhaul/Assembly/Shift Control Housing Assemble).
2. Remove the masking from the control lever opening and ensure the sealing surface is clean and
dry.
3. Place the control lever gasket on to the transmission. 4. Position the control lever housing
assembly to the control lever assembly opening, aligning the bushing with the internal shift control
lever.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift
Boot, M/T > Component Information > Service and Repair > Page 5758
5. Install the control lever housing assembly bolts and tighten to 20 Nm (15 lb ft).
6. Slide the boot into position over the control lever.
Note: Ensure the carpet is not between the boot and the floor panel.
7. Tilt the boot in order to seat to the floor. 8. Install the control lever boot screws and tighten to 2.5
Nm (22 lb in). 9. Install the console (w/o D06 only). Refer to Console Replacement (Large
w/Manual or Auto Transmission) (See: Body and Frame/Interior
Moulding / Trim/Console/Service and Repair)Console Replacement (Small w/Manual
Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair).
10. Install the shift lever assembly. Refer to Shift Lever Assembly Replacement (w/o D06) (See:
Shifter M/T/Service and Repair/Shift Lever
Assembly Replacement (w/o D06))Shift Lever Assembly Replacement (D06) (See: Shifter
M/T/Service and Repair/Shift Lever Assembly Replacement (D06)).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T
> Component Information > Service and Repair > Transmission Mount Replacement (RPO Z71)
Transmission Mount: Service and Repair Transmission Mount Replacement (RPO Z71)
Transmission Mount Replacement (RPO Z71)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Support the transmission with a transmission
jack. 3. Remove the two nuts (1) securing the transmission mount to the transmission support. 4.
Raise the transmission off of the transmission support.
5. Remove the mount to transmission bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T
> Component Information > Service and Repair > Transmission Mount Replacement (RPO Z71) > Page 5763
6. Remove the mount spacer.
Installation Procedure
1. Install the mount spacer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T
> Component Information > Service and Repair > Transmission Mount Replacement (RPO Z71) > Page 5764
2. Install the transmission mount to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the mount to transmission bolts and tighten to 55 Nm (41 lb ft).
4. Lower the transmission and install the two nuts (1) securing the transmission mount to the
transmission support. Tighten the nuts to 57 Nm (42 lb
ft).
5. Remove the transmission jack. 6. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T
> Component Information > Service and Repair > Transmission Mount Replacement (RPO Z71) > Page 5765
Transmission Mount: Service and Repair Transmission Mount Replacement (RPO Z85 and ZQ8)
Transmission Mount Replacement (RPO Z85 and ZQ8)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Support the transmission with a transmission
jack. 3. Remove the two nuts (1) securing the transmission mount to the transmission support. 4.
Raise the transmission off of the transmission support.
5. Remove the mount to transmission bolts.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T
> Component Information > Service and Repair > Transmission Mount Replacement (RPO Z71) > Page 5766
1. Install the transmission mount to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the mount to transmission bolts and tighten to 55 Nm (41 lb ft).
3. Lower the transmission and install the two nuts (1) securing the transmission mount to the
transmission support. Tighten the nuts to 57 Nm (42 lb
ft).
4. Remove the transmission jack. 5. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams
Control Module: Diagrams
Component Connector End Views
Transmission Control Module (TCM) (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 5772
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 5773
Control Module: Service and Repair
Transmission Control Module Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations
Fluid Pressure Sensor/Switch: Locations
Powertrain Component Views
Inside the Transmission Components (M30)
36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift
Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid
Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC)
Pulse Width Modulation (PWM) Solenoid Valve
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 5779
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (M30)
Description Location
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations
Transmission Position Switch/Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Left Side of the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
5783
1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
5784
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
5785
Transmission Position Switch/Sensor: Diagrams
Component Connector End Views
Park/Neutral Position (PNP) Switch (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
5786
Transmission Position Switch/Sensor: Service and Repair
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
2. Remove the following parts: (89), (92), (88), (85) and (84)
3. Remove the manual shaft seal (82) with a screwdriver.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
5787
1. Inspect the following items:
* Manual shaft (84) for damage or burrs
* Parking lock actuator assembly (85) for damage
* Manual shift detent lever with shaft position switch assembly (88) for damage or cracks
* Manual valve link (89) for damage
* Manual shift detent lever pin (92) discard - Do NOT reuse.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the following items:
* Manual shift detent lever with shaft position switch assembly (88)
* Parking lock actuator assembly (85)
* Manual shaft (84) (model dependent)
* NEW manual shift detent lever pin (92)
* Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft).
3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams
Transmission Speed Sensor: Diagrams
Component Connector End Views
Automatic Transmission Input Shaft Speed (ISS) Sensor (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams
Clutch Pedal Position Sensor / Switch: Diagrams
Component Connector End Views
Clutch Pedal Position (CPP) Sensor (MA5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 5798
Clutch Pedal Position Sensor / Switch: Service and Repair
Clutch Pedal Position Switch Replacement
Removal Procedure
1. Disconnect the electrical connector (2) from the clutch pedal position switch (1).
2. Push the clutch pedal position switch retaining plate locking tabs (2) inward toward each other to
release. 3. Remove the clutch pedal position switch (3) from the clutch pedal assembly (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 5799
1. Slide the clutch pedal position switch (3) with retaining plate (2) into the clutch pedal bracket (1),
until the locking tabs (2) are fully engaged.
2. Connect the electrical connector (2) to the clutch pedal position switch (1). 3. Complete the
following in order to adjust the clutch pedal position switch (1).
1. Push the switch fully into the bracket, allowing the switch to ratchet in the retaining plate. 2.
Depress the clutch pedal all the way to the floor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams
Pressure Regulating Solenoid: Diagrams
Component Connector End Views
Pressure Control (PC) Solenoid Valve (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Locations
Shift Interlock Solenoid: Locations
Instrument Panel/Center Console Component Views
Behind the Left Side of the I/P Components
1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal
Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition
Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Locations > Page 5809
Shift Interlock Solenoid: Diagrams
Component Connector End Views
Automatic Transmission Shift Lock Control Solenoid (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Locations > Page 5810
Shift Interlock Solenoid: Service and Repair
Automatic Transmission Shift Lock Control Actuator Replacement
Removal Procedure
Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the
shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic
transmission shift lock control actuator away from the steering column jacket and the cable shift
cam
assembly.
6. Remove the automatic transmission shift lock control actuator.
Installation Procedure
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1. Firmly install the automatic transmission shift lock control actuator onto the steering column
jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control
actuator electrical connector.
3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the
neutral position) in the following way:
1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control
actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which
disengages the adjuster teeth. Slide the adjuster block (2) as far
away from the actuator as possible.
3. Lock the adjuster block (2) in place by pushing in on the tab (1).
4. Inspect the automatic transmission shift lock control actuator for the following items:
1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the
shift lever clevis is put into the park position. 2. Turn the ignition to the ON position and depress the
brake pedal to move the shift lever out of the park position. The actuator will be
energized.
3. Readjust the automatic transmission shift lock control actuator if needed.
5. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Specifications
Shift Solenoid: Specifications
Shift Solenoid Valve State and Gear Ratio
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
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Diagram Information and Instructions > Page 5824
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Diagram Information and Instructions > Page 5825
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Diagram Information and Instructions > Page 5827
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Diagram Information and Instructions > Page 5828
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Diagram Information and Instructions > Page 5830
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Diagram Information and Instructions > Page 5831
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Diagram Information and Instructions > Page 5832
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Diagram Information and Instructions > Page 5833
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Diagram Information and Instructions > Page 5834
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Diagram Information and Instructions > Page 5835
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Diagram Information and Instructions > Page 5836
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Diagram Information and Instructions > Page 5837
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Diagram Information and Instructions > Page 5838
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Diagram Information and Instructions > Page 5839
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Diagram Information and Instructions > Page 5840
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Diagram Information and Instructions > Page 5841
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Diagram Information and Instructions > Page 5842
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Diagram Information and Instructions > Page 5843
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 5844
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 5845
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 5846
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Diagram Information and Instructions > Page 5847
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Diagram Information and Instructions > Page 5848
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 5849
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Diagram Information and Instructions > Page 5850
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Diagram Information and Instructions > Page 5852
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Diagram Information and Instructions > Page 5853
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Diagram Information and Instructions > Page 5854
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Diagram Information and Instructions > Page 5855
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Diagram Information and Instructions > Page 5857
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Diagram Information and Instructions > Page 5861
Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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Diagram Information and Instructions > Page 5870
diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Diagram Information and Instructions > Page 5880
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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Diagram Information and Instructions > Page 5940
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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Diagram Information and Instructions > Page 5955
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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Diagram Information and Instructions > Page 5975
6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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Diagram Information and Instructions > Page 5976
repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Diagram Information and Instructions > Page 5977
Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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Diagram Information and Instructions > Page 5978
8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Diagram Information and Instructions > Page 5979
13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Diagram Information and Instructions > Page 5980
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Diagram Information and Instructions > Page 5981
Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Diagram Information and Instructions > Page 5982
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
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Diagram Information and Instructions > Page 5983
Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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Diagram Information and Instructions > Page 5984
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
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Diagram Information and Instructions > Page 5985
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
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Diagram Information and Instructions > Page 5986
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Diagram Information and Instructions > Page 5987
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Diagram Information and Instructions > Page 5988
Shift Solenoid: Connector Views
Component Connector End Views
1-2 Shift Solenoid (SS) Valve (M30)
2-3 Shift Solenoid (SS) Valve (M30)
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Diagram Information and Instructions > Page 5989
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Page 5990
Shift Solenoid: Service and Repair
Control and Shift Solenoids Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator
is necessary only if servicing the pressure control solenoid.
2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and
Gaskets (See: Automatic
Transmission/Transaxle/Accumulator/Service and Repair).
3. Disconnect all the internal wiring harness electrical connectors from the electrical components
(1-6).
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4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). 5. Remove the
pressure control solenoid (377).
Note the orientation upon removal.
6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids.
Installation Procedure
Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined
(cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as
the valve body bolts are tightened and damage may occur.
1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers.
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Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the following items:
1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug
(376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid
retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in)
4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6).
5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See:
Automatic
Transmission/Transaxle/Accumulator/Service and Repair).
6. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Automatic
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Transmission/Transaxle/Service and Repair/Removal and Replacement).
7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to
Transmission Fluid Check (See: Automatic
Transmission/Transaxle/Testing and Inspection/Component Tests and General
Diagnostics/Transmission Fluid Check).
Note: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
engine control module (ECM), powertrain control module (PCM) or transmission control module
(TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP
values are learned.
8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions).
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Torque Converter Clutch Solenoid: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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Information > Diagrams > Diagram Information and Instructions > Page 6057
View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Information > Diagrams > Diagram Information and Instructions > Page 6155
Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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Information > Diagrams > Diagram Information and Instructions > Page 6156
6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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Information > Diagrams > Diagram Information and Instructions > Page 6157
repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Information > Diagrams > Diagram Information and Instructions > Page 6158
Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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Information > Diagrams > Diagram Information and Instructions > Page 6159
8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information > Diagrams > Diagram Information and Instructions > Page 6160
13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Information > Diagrams > Diagram Information and Instructions > Page 6162
Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information > Diagrams > Diagram Information and Instructions > Page 6163
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
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Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6166
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6167
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6168
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6169
Torque Converter Clutch Solenoid: Connector Views
Component Connector End Views
Torque Converter Clutch (TCC) Solenoid Valve (M30)
Wiring Diagram
Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6170
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 6171
Torque Converter Clutch Solenoid: Service and Repair
Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and
Wiring Harness
Special Tools
J 28458 Seal Protector Retainer Installer
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter.
Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
3. Disconnect the transmission harness 20 way connector from the transmission internal harness
pass-through connector.
Depress both tabs on the connector and pull straight up. Do not pry the connector.
Note: Removal of the valve body is not necessary for the following procedure.
4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator
Assembly, Spacer Plate, and Gaskets (See:
Automatic Transmission/Transaxle/Accumulator/Service and Repair).
5. Disconnect all the internal wiring harness electrical connectors from the electrical components
(1-6).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 6172
6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access
one of the TCC solenoid retaining bolts.
8. Remove the TCC solenoid bolts (68).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 6173
9. Remove the TCC solenoid and wiring harness (66).
Turn the wiring harness over so the wiring harness hangs down.
10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the
pressure control solenoid (377).
Note the orientation upon removal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 6174
12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal
wiring harness.
13. Using J 28458 , release the pass-through electrical connector from the transmission case.
1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4
tabs retaining the connector. 3. Pull the harness connector down through the transmission case.
14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the
transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following
defects:
* Damage
* Cracked connectors
* Exposed wires
* Loose pins
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 6175
1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the
transmission. 2. Install the pass-through electrical connector to the transmission case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid
retaining bolts. 4. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 5. Tighten the
TCC solenoid retaining bolts to 11 Nm (97 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 6176
Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined
(cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as
the valve body bolts are tightened and damage may occur.
6. Install the following items:
1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug
(376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid
retainer (378) 7. The solenoid retainer bolt (364)
Tighten the solenoid retainer bolt to 11 Nm (97 lb in)
7. Install the TCC PWM solenoid to the control valve body. 8. Install the TCC PWM solenoid
retainer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 6177
9. Connect all the internal wiring harness electrical connectors to the electrical components (1-6).
10. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See:
Automatic
Transmission/Transaxle/Accumulator/Service and Repair).
11. Connect the transmission harness 20 way connector to the transmission pass-through
connector.
Align the arrows on each half of the connector and insert straight down.
12. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) VI transmission
fluid. Refer to Transmission Fluid Check (See: Automatic
Transmission/Transaxle/Testing and Inspection/Component Tests and General
Diagnostics/Transmission Fluid Check).
Note: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
engine control module (ECM), powertrain control module (PCM) or transmission control module
(TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP
values are learned.
15. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information
> Service and Repair
Actuator: Service and Repair
Electric Motor Actuator Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine protection shield (EPS).
Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service
and
Repair).
3. Remove the electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information
> Service and Repair > Page 6182
4. Remove the electric motor actuator.
Installation Procedure
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
Note: Apply TEFLON(TM) tape to the threads of the electric actuator motor before installation.
1. Install the electric motor actuator and tighten to 22 Nm (16 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information
> Service and Repair > Page 6183
2. Install the electrical connector.
3. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid Plate/Service and Repair). 4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams
Control Module: Diagrams
Component Connector End Views
Transmission Control Module (TCM) (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Page 6189
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Page 6190
Control Module: Service and Repair
Transmission Control Module Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Locations
Fluid Pressure Sensor/Switch: Locations
Powertrain Component Views
Inside the Transmission Components (M30)
36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift
Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid
Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC)
Pulse Width Modulation (PWM) Solenoid Valve
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Locations > Page 6196
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (M30)
Description Location
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations
Transmission Position Switch/Sensor: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Left Side of the Transmission Components (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6200
1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch
Rear of the Transmission Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6201
1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle
Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel
Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6202
Transmission Position Switch/Sensor: Diagrams
Component Connector End Views
Park/Neutral Position (PNP) Switch (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6203
Transmission Position Switch/Sensor: Service and Repair
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
2. Remove the following parts: (89), (92), (88), (85) and (84)
3. Remove the manual shaft seal (82) with a screwdriver.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6204
1. Inspect the following items:
* Manual shaft (84) for damage or burrs
* Parking lock actuator assembly (85) for damage
* Manual shift detent lever with shaft position switch assembly (88) for damage or cracks
* Manual valve link (89) for damage
* Manual shift detent lever pin (92) discard - Do NOT reuse.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the following items:
* Manual shift detent lever with shaft position switch assembly (88)
* Parking lock actuator assembly (85)
* Manual shaft (84) (model dependent)
* NEW manual shift detent lever pin (92)
* Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft).
3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter
Replacement (See: Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams
Transmission Speed Sensor: Diagrams
Component Connector End Views
Automatic Transmission Input Shaft Speed (ISS) Sensor (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component
Information > Diagrams
Clutch Pedal Position Sensor / Switch: Diagrams
Component Connector End Views
Clutch Pedal Position (CPP) Sensor (MA5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component
Information > Diagrams > Page 6215
Clutch Pedal Position Sensor / Switch: Service and Repair
Clutch Pedal Position Switch Replacement
Removal Procedure
1. Disconnect the electrical connector (2) from the clutch pedal position switch (1).
2. Push the clutch pedal position switch retaining plate locking tabs (2) inward toward each other to
release. 3. Remove the clutch pedal position switch (3) from the clutch pedal assembly (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component
Information > Diagrams > Page 6216
1. Slide the clutch pedal position switch (3) with retaining plate (2) into the clutch pedal bracket (1),
until the locking tabs (2) are fully engaged.
2. Connect the electrical connector (2) to the clutch pedal position switch (1). 3. Complete the
following in order to adjust the clutch pedal position switch (1).
1. Push the switch fully into the bracket, allowing the switch to ratchet in the retaining plate. 2.
Depress the clutch pedal all the way to the floor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems >
Acceleration/Deceleration Sensor > Component Information > Service and Repair
Acceleration/Deceleration Sensor: Service and Repair
Longitudinal Accelerometer Replacement
Removal Procedure
1. Remove the left front seat. Refer to Front Seat Replacement - Bucket (See: Body and
Frame/Seats/Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split
Bench Seat Replacement).
2. Access the sensor through service slit provided in the carpet. 3. Disconnect the longitudinal
accelerometer electrical connector.
4. Remove the nuts (1) from the longitudinal accelerometer. 5. Remove the longitudinal
accelerometer.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems >
Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 6222
1. Install the longitudinal accelerometer.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the longitudinal accelerometer nuts (1) and tighten to 9 Nm (80 lb in). 3. Connect the
longitudinal accelerometer electrical connector. 4. Install the left front seat. Refer to Front Seat
Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split
Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 6227
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 6228
Electronic Brake Control Module: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 6229
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 6230
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Page 6231
Electronic Brake Control Module: Diagrams
Component Connector End Views
Electronic Brake Control Module (EBCM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Page 6232
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Page 6233
Electronic Brake Control Module: Service and Repair
Electronic Brake Control Module Replacement
Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service
Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
1. Turn the ignition switch to the OFF position. 2. Remove the brake pressure modulator valve
(BPMV). Refer to Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly
- Antilock Brakes/Service and Repair).
3. Remove the electronic brake control module (EBCM) bolts (1).
Discard the bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Page 6234
4. Carefully separate the EBCM (1) from the BPMV. 5. Remove the 12 EBCM to BPMV seals (2).
Installation Procedure
1. Carefully install the EBCM (1) and the 12 seals (2) to the BPMV.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: Do not reuse the EBCM bolts. Install new bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Page 6235
2. Install new EBCM bolts (1) and tighten to 2 Nm (18 lb in). 3. Install the EBCM/BPMV assembly to
the vehicle. Refer to Brake Pressure Modulator Valve Replacement (See: Hydraulic Control
Assembly Antilock Brakes/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Brake Pressure Modulator Valve Replacement
Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service
Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
1. Turn the ignition switch to the OFF position. 2. Disconnect the electronic brake control module
(EBCM) electrical connector.
3. Clean the area around the brake pipe fittings and the EBCM and the brake pressure modulator
valve (BPMV) mating surfaces of any accumulated
dirt and debris.
4. Disconnect the RF brake pipe fitting (1) from the EBCM/BPMV assembly.
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and
contamination.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6239
5. Disconnect the RR brake pipe fitting (1) from the EBCM/BPMV assembly.
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and
contamination.
6. Disconnect the LR brake pipe fitting (1) from the EBCM/BPMV assembly.
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and
contamination.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6240
7. Disconnect the LF brake pipe fitting (1) from the EBCM/BPMV assembly.
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and
contamination.
8. Disconnect the master cylinder primary brake pipe fitting (1) from the EBCM/BPMV assembly.
Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and
contamination.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6241
9. Disconnect the master cylinder secondary brake pipe fitting (1) from the EBCM/BPMV assembly.
Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and
contamination.
10. Remove the EBCM/BPMV assembly bracket nuts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6242
11. Remove the EBCM/BPMV assembly (1).
12. If necessary, remove the BPMV bracket bolts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6243
13. If necessary, remove the bracket (1) from the BPMV. 14. Remove the EBCM. Refer to
Electronic Brake Control Module Replacement (See: Electronic Brake Control Module/Service and
Repair).
Installation Procedure
1. Install the EBCM. Refer to Electronic Brake Control Module Replacement (See: Electronic Brake
Control Module/Service and Repair).
2. If removed, install the bracket (1) to the BPMV.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6244
3. If removed, install the BPMV bracket bolts (1) and tighten to 11 Nm (97 lb in).
4. Install the EBCM/BPMV assembly (1) to the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6245
5. Install the EBCM/BPMV assembly bracket nuts (1) and tighten to 9 Nm (80 lb in).
Connect the master cylinder secondary brake pipe fitting (1) to the EBCM/BPMV assembly and
tighten to 32 Nm (24 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6246
Connect the master cylinder primary brake pipe fitting (1) to the EBCM/BPMV assembly and
tighten to 32 Nm (24 lb ft).
Connect the LF brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6247
Connect the LR brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb ft).
6. Connect the RR brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb
ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6248
7. Connect the RF brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb
ft). 8. Connect the EBCM electrical connector. 9. Perform the Antilock Brake System Automated
Bleed Procedure (See: Brake Bleeding/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral
Accelerometer > Component Information > Locations
Lateral Accelerometer: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral
Accelerometer > Component Information > Locations > Page 6252
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral
Accelerometer > Component Information > Locations > Page 6253
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral
Accelerometer > Component Information > Locations > Page 6254
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral
Accelerometer > Component Information > Locations > Page 6255
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral
Accelerometer > Component Information > Locations > Page 6256
Lateral Accelerometer: Diagrams
Component Connector End Views
Yaw and Lateral Accelerometer Sensor (2WD) (JL4)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction
Control Switch > Component Information > Diagrams
Traction Control Switch: Diagrams
Component Connector End Views
Traction Control Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction
Control Switch > Component Information > Diagrams > Page 6260
Traction Control Switch: Service and Repair
Electronic Traction Control Switch Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
Wheel Speed Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6265
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6266
Wheel Speed Sensor: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6267
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6268
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6269
Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views
Wheels/Vehicle Underbody Component Views
Front Wheel Knuckle Components
1 - Wheel Speed Sensor (WSS) - Right Front 2 - Wheel Speed Sensor (WSS) - Left Front
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Page 6270
Wheel Speed Sensor: Diagrams
Component Connector End Views
Wheel Speed Sensor (WSS) - Left Front
Wheel Speed Sensor (WSS) - Right Front
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Page 6271
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement
Front Wheel Speed Sensor Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
1. Within the engine compartment, disconnect the wheel speed sensor electrical connector (1). 2.
Release the wheel speed sensor harness connector from the wheelhouse. 3. Raise and support
the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and
Repair). 4. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation
(See: Maintenance/Wheels and Tires/Service and Repair
).
5. Release the wheel speed sensor harness clips (1) from the suspension upper control arm.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6274
6. Release the wheel speed sensor harness grommet (1) from the mounting bracket.
7. Remove the wheel speed sensor harness bracket bolt (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6275
8. Thoroughly clean the wheel speed sensor mounting area of the steering knuckle of any dirt and
debris. 9. Remove the wheel speed sensor bolt (1).
Note: Do not pry or lever against the wheel speed sensor to remove.
10. Carefully remove the wheel speed sensor from the suspension knuckle by pulling straight
upward.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6276
1. Install the wheel speed sensor to the suspension knuckle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the wheel speed sensor bolt (1) and tighten to 8 Nm (71 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6277
3. Install the wheel speed sensor harness bracket bolt (1) and tighten to 9 Nm (80 lb in).
4. Install the wheel speed sensor harness grommet (1) to the mounting bracket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6278
5. Install the wheel speed sensor harness clips (1) to the suspension upper control arm.
6. Install the wheel speed sensor harness connector to the wheelhouse. 7. Connect the wheel
speed sensor electrical connector (1). 8. Install the tire and wheel assembly. Refer to Tire and
Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9.
Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnostic System
Check - Vehicle).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6279
Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement
Rear Wheel Speed Sensor Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the wheel speed sensor bolts (1).
3. Remove the wheel speed sensor (1) from the drum brake backing plate by carefully pulling
straight outward.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6280
4. Release the wheel speed sensor harness retainers (1) on the rear park brake cable.
Release the harness from the retainers.
5. Disconnect the wheel speed sensor electrical connector (1). 6. Release the electrical connector
and harness retainer (2) from the frame. 7. Remove the wheel speed sensor assembly.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6281
1. Position the wheel speed sensor assembly to the vehicle. 2. Connect the wheel speed sensor
electrical connector (1). 3. Install the electrical connector and harness retainer (2) to the frame.
4. Position the wheel speed sensor harness to the retainers (1) on the rear park brake cable. 5.
Fasten the wheel speed sensor harness retainers.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6282
6. Install the wheel speed sensor (1) to the drum brake backing plate.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. Install the wheel speed sensor bolts (1) and tighten to 17 Nm (13 lb ft). 8. Lower the vehicle. 9.
Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnostic System
Check - Vehicle).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
Sensor > Component Information > Locations
Yaw Rate Sensor: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
Sensor > Component Information > Locations > Page 6286
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
Sensor > Component Information > Locations > Page 6287
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
Sensor > Component Information > Locations > Page 6288
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
Sensor > Component Information > Locations > Page 6289
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
Sensor > Component Information > Locations > Page 6290
Yaw Rate Sensor: Diagrams
Component Connector End Views
Yaw and Lateral Accelerometer Sensor (2WD) (JL4)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
Sensor > Component Information > Locations > Page 6291
Yaw Rate Sensor: Service and Repair
Vehicle Yaw Sensor Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Customer Interest: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel
Brake Bleeding: Customer Interest Brakes - Brake Pedal Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Customer Interest: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page
6300
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Customer Interest: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page
6301
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal
Spongy/Increased Pedal Travel
Brake Bleeding: All Technical Service Bulletins Brakes - Brake Pedal Spongy/Increased Pedal
Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal
Spongy/Increased Pedal Travel > Page 6307
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal
Spongy/Increased Pedal Travel > Page 6308
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By
Various Control Modules
Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control
Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By
Various Control Modules > Page 6314
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By
Various Control Modules > Page 6315
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By
Various Control Modules > Page 6316
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair
Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 6321
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 6322
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 6323
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 6324
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 6325
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 6326
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC
P2138/Reduced Power
Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced
Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC
P2138/Reduced Power > Page 6331
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6332
Brake Bleeding: By Symptom
Technical Service Bulletin # 09-05-25-003 Date: 090921
Brakes - Brake Pedal Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6333
List of Affected Units
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6334
Disclaimer
Technical Service Bulletin # 09-05-25-003 Date: 090921
Brakes - Brake Pedal Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6335
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6336
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 09-05-25-003 Date: 090921
Brakes - Brake Pedal Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6337
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6338
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure
Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure
Antilock Brake System Automated Bleed Procedure
Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
Note: The base hydraulic brake system must be bled before performing this automated bleeding
procedure. If you have not yet performed the base hydraulic brake system bleeding procedure,
refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding
(Pressure) ( See: ) before proceeding.
1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the
brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the
automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated
bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF.
7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the
maximum-fill level with Delco Supreme 11(R) GM P/N 12377967 (Canadian P/N 992667) or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See:
)Hydraulic Brake System Bleeding (Pressure) (
See: ).
10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in
order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal.
Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated
bleeding procedure. If the brake pedal still feels spongy after repeating the automated
bleeding procedure inspect the brake system for external leaks. Refer to Brake System External
Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General
Diagnostics/Brake System External Leak Inspection).
13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp
remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the
vehicle to be driven until it is diagnosed and repaired. Refer to
Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related
Diagnostic Procedures/Symptoms - Hydraulic Brakes).
15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake
pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a
firm brake pedal is obtained.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 6341
Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding
Manual
Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See:
Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With
the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, you
must perform the following steps:
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add
GM approved brake fluid from a clean,
sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (See:
Maintenance/Service Intervals). If removal of the reservoir cap and diaphragm is necessary, clean
the outside of the reservoir on and around the cap prior to removal.
2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
brake pipe from the front port of the brake
master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4.
Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant
slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the
same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe,
then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps
3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe
installed securely to the master cylinder, after all air has been purged from the front port of the
master cylinder,
loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8.
10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake
pipe-to-master cylinder fittings are properly
tightened.
4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake
fluid container. Refer to Master Cylinder
Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and
Repair/Procedures/Master Cylinder Reservoir Filling). Ensure that the brake master cylinder
reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain
the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to
removing the cap and diaphragm.
5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6.
Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the
transparent hose into a transparent container partially filled with GM approved brake fluid from a
clean, sealed
brake fluid container. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service
Intervals).
8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the
pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit.
10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15
seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12.
With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been
purged from the right rear hydraulic circuit install
a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With
the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left
rear hydraulic circuit, install a proper
box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With
the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the right front hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly
tightened.
19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid
from a clean, sealed brake fluid container. Refer
to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and
Repair/Procedures/Master Cylinder Reservoir Filling).
20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the
brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy
after repeating the bleeding procedure,
perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Hydraulic System/Testing and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 6342
Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection).
2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in
the system.
22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven
until it is diagnosed and repaired.
23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes
(See: Hydraulic System/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes).
Pressure
Hydraulic Brake System Bleeding (Pressure)
Special Tools
* J-29532 - Diaphragm Pressure Bleeder, or equivalent
* J-35589-A - Brake Pressure Bleeder Adapter
Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety
Information/Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With
the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, you
must perform the following steps:
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add
GM approved brake fluid from a clean,
sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Hydraulic
System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). If
removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and
around the cap prior to removal.
2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
brake pipe from the front port of the brake
master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4.
Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant
slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the
same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe,
then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps
3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe
installed securely to the master cylinder, after all air has been purged from the front port of the
master cylinder,
loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8.
10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake
pipe-to-master cylinder fittings are properly
tightened.
4. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid
from a clean, sealed brake fluid container.
Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and
diaphragm.
5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6.
Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or
equivalent. Add GM approved brake fluid from a
clean, sealed brake fluid container as necessary to bring the level to approximately the half-full
point.
7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, to the
J-35589-A - Brake Pressure Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Pressure
Bleeder, or equivalent , or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 Diaphragm Pressure Bleeder, or equivalent , or equivalent, fluid tank valve to allow pressurized
brake fluid to enter the brake
system.
10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to
ensure that there are no existing external brake fluid
leaks. Any brake fluid leaks identified require repair prior to completing this procedure.
11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the
transparent hose into a transparent container partially filled with GM approved brake fluid from a
clean, sealed
brake fluid container.
14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air
bubbles stop flowing from the bleeder, then
tighten the bleeder valve.
15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been
purged from the right rear hydraulic circuit,
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 6343
install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With
the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the left rear hydraulic circuit, install a
proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With
the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the right front hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly
tightened.
22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, fluid tank valve,
then disconnect the J-29532 - Diaphragm
Pressure Bleeder, or equivalent , or equivalent, from the J-35589-A - Brake Pressure Bleeder
Adapter.
23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder
reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved
brake fluid from a clean, sealed brake fluid container. Refer
to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and
Repair/Procedures/Master Cylinder Reservoir Filling)
25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the
brake pedal feels spongy perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Hydraulic System/Testing and
Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection).
2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove
any air that may have been trapped in the brake
pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed Procedure
(See: ).
27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven
until it is diagnosed and repaired.
28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes
(See: Hydraulic System/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 6344
Brake Bleeding: Service and Repair Hydraulic Brake System Flushing
Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Service
Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
* Fluid separation, indicating two types of fluid are present; a substance other than the
recommended brake fluid has been introduced into the brake hydraulic system
- Swirled appearance - oil-based substance
- Layered appearance - silicone-based substance
* Fluid discoloration, indicating the presence of moisture or particles that have been introduced into
the brake hydraulic system
- Cloudy appearance - moisture
- Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating brake fluid
contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated
by fluid separation and/or a swollen master
cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform
the following:
1. Remove ALL of the following components listed from the vehicle. Each component contains
internal rubber seals/linings which have been
contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the
procedures indicated:
* Master Cylinder Replacement (See: Hydraulic System/Brake Master Cylinder/Service and
Repair/Removal and Replacement/Master Cylinder Replacement)
* Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Rear Brake Hose Replacement)
* Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and Repair/Brake
Caliper Replacement)
* Wheel Cylinder Replacement (See: Drum Brake System/Wheel Cylinder/Service and Repair)
* Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control
Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair)
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake
pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed
and install them to the vehicle. Each component contains internal rubber
seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic
system. Refer to the procedures indicated:
* Master Cylinder Replacement (See: Hydraulic System/Brake Master Cylinder/Service and
Repair/Removal and Replacement/Master Cylinder Replacement) ; also perform the following:
Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the
reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and
replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Hydraulic
System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder
Reservoir Replacement). Replace the brake master cylinder reservoir cap diaphragm.
* Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Rear Brake Hose Replacement)
* Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and Repair/Brake
Caliper Replacement)
* Wheel Cylinder Replacement (See: Drum Brake System/Wheel Cylinder/Service and Repair) , if
equipped
* Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control
Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair)
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but
WAS contaminated with water or dirt, rust,
corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The
diaphragm may have allowed the moisture or particles to enter the hydraulic system.
5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM
P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 6345
6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder
reservoir filled to the maximum-fill level with the correct
brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic
Brake System Bleeding (Pressure) (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and
Repair
Brake Pedal Assy: Service and Repair
Brake Pedal Assembly Replacement
Removal Procedure
1. Remove the steering column. Refer to Steering Column Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and
Repair/Steering Column Replacement).
2. Disconnect the stoplamp switch electrical connectors.
3. Remove the brake booster pushrod retainer (1).
4. Remove the brake booster pushrod clevis pin (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and
Repair > Page 6349
5. Remove the upper brake pedal bracket bolts (1).
6. Remove the power vacuum brake booster nuts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and
Repair > Page 6350
7. Remove the brake pedal assembly (1).
Installation Procedure
1. Install the brake pedal assembly (1).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and
Repair > Page 6351
2. Install the power vacuum brake booster nuts (1) and tighten to 20 Nm (15 lb ft).
3. Install the upper brake pedal bracket bolts (1) and tighten to 27 Nm (20 lb ft.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and
Repair > Page 6352
4. Install the brake booster pushrod clevis pin (1) to the pushrod and the brake pedal.
5. Install the brake booster pushrod retainer (1). 6. Connect the stoplamp switch electrical
connectors. 7. Install the steering column. Refer to Steering Column Replacement (See: Steering
and Suspension/Steering/Steering Column/Service and
Repair/Steering Column Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Testing and Inspection
Brake Caliper: Testing and Inspection
Brake Caliper Inspection Warning: Refer to Brake Dust Warning (See: Service
Precautions/Technician Safety Information/Brake Dust Warning).
1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these
conditions are present, the brake caliper requires
replacement.
2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper
seating in the caliper body. If any of these
conditions are present, the brake caliper requires overhaul or replacement.
3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake
pads. If there is any evidence of brake fluid
leakage, the brake caliper requires overhaul or replacement.
4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores:
The movement of the caliper pistons into the caliper bores should be smooth and even. If the
caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement.
* For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in
front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against
the brake pad or block of wood, slowly bottom the piston in the bore.
* For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in
front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against
the brake pad or block of wood, slowly bottom the pistons evenly into the bores.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement
Brake Caliper: Service and Repair Brake Caliper Replacement
Brake Caliper Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety
Information/Brake Fluid Irritant Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair) 2. Remove the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair
).
Note: Do not reuse the brake hose fitting gaskets.
3. Remove the brake hose fitting bolt (1), the brake hose fitting gaskets (2), and the brake hose
fitting (3) from the brake caliper.
Cap the brake hose fitting to prevent brake fluid loss and contamination.
4. Discard the brake hose fitting gaskets.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement > Page 6359
5. Remove the brake caliper guide pin bolts (1).
6. Remove the brake caliper (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement > Page 6360
1. Install the brake caliper (1).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the brake caliper guide pin bolts (1) and tighten to 64Nm (47 lb ft).
Note: Install new brake hose fitting gaskets.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement > Page 6361
3. Assemble the brake hose fitting bolt (1) and new brake hose fitting gaskets (2) to the brake hose
fitting (3). 4. Install the brake hose assembly to the brake caliper and tighten the fitting bolt to 40
Nm (30 lb ft). 5. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding
(Manual) (See: Brake Bleeding/Service and Repair)Hydraulic
Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair).
6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement > Page 6362
Brake Caliper: Service and Repair Brake Caliper Bracket Replacement
Brake Caliper Bracket Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair
).
Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support
the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which
may cause damage to the brake hose and in turn may cause a brake fluid leak.
3. Without disconnecting the front brake hose, remove the brake caliper and support with heavy
mechanics wire or equivalent. Refer to Brake Caliper
Replacement (See: Brake Caliper Replacement).
4. Remove the 2 brake caliper bracket bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement > Page 6363
5. Remove the brake caliper bracket. 6. Inspect the disc brake hardware for damage and replace, if
necessary. Refer to Disc Brake Mounting and Hardware Inspection (See: Testing and
Inspection/Component Tests and General Diagnostics).
Installation Procedure
1. Install the brake caliper bracket.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement > Page 6364
2. Install the 2 brake caliper bracket bolts and tighten to 180 Nm (133 lb ft). 3. Install the brake
caliper. Refer to Brake Caliper Replacement (See: Brake Caliper Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications
Brake Pad: Specifications
Minimum Pad Thickness
............................................................................................................................... 1.40 mm (0.055
in) from the mounting plates.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > Page 6368
Brake Pad: Testing and Inspection
Brake Pad Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
* Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are
removed from the vehicle.
* If replacement is necessary, always replace disc brake pads in axle sets.
* Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally
occurs at the leading edge of the disc brake pads.
* Inspect the thickness of the disc brake pads (3) in order to ensure that they have not worn
prematurely. The disc brake pad wear should be approximately even per axle set.
* Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake
pad wear reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor
(2). The wear indicator will then produce an audible, high-pitched warning noise during wheel
rotation.
* Replace the disc brake pads when the friction surface (3) is worn to within 1.40 mm (0.055 in) of
the mounting plates.
* Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake
pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure
the gap between the surfaces. If more than 0.13 mm (0.005 in) gap exists midway between the
length of the disc brake pads, replace the disc brake pads.
* Verify that any disc brake pad shims that may be required are in place and not damaged or
excessively corroded. Replace any missing or damaged shims in order to preserve proper disc
brake performance.
* Replace the disc brake pads if any have separated from the mounting plates.
* Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause
noise or otherwise impair disc brake performance.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Brake Pads Replacement
Brake Pad: Service and Repair Brake Pads Replacement
Brake Pads Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
1. Inspect the fluid level in the master cylinder reservoir. 2. If the brake fluid is midway between the
maximum full point and the minimum allowable level, no brake fluid needs to be removed from the
reservoir before proceeding.
3. If the brake fluid is higher than midway between the maximum full point and the minimum
allowable level, remove brake fluid to the midway
point before proceeding.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair
).
6. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear
of the caliper body and against the outboard brake
pad.
7. Tighten the C-clamp evenly until the caliper pistons are compressed into the caliper bore.
8. Remove the lower brake caliper guide pin bolt (1).
Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support
the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which
may cause damage to the brake hose and in turn may cause a brake fluid leak.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Brake Pads Replacement > Page 6371
9. Pivot the brake caliper (1) upward and support with heavy mechanics wire or equivalent.
10. Remove the outer brake pad (1). 11. Remove the inner brake pad. (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Brake Pads Replacement > Page 6372
12. If installing new disc brake pads, remove and discard the brake pad shims (1). 13. Thoroughly
clean the brake caliper bracket mating surfaces and, if reusing the brake pads, clean the brake pad
shims with denatured alcohol and
allow to dry.
Installation Procedure
1. If installing new disc brake pads, install new brake pad shims (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Brake Pads Replacement > Page 6373
2. Install the outer brake pad (1). 3. Install the inner brake pad. (2).
Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support
the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which
may cause damage to the brake hose and in turn may cause a brake fluid leak.
4. Pivot the brake caliper (1) downward and position to the brake caliper bracket.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Brake Pads Replacement > Page 6374
5. Install the lower brake caliper guide pin bolt (1) and tighten to 64 Nm (47 lb ft). 6. Install the tire
and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels
and Tires/Service and Repair). 7. Lower the vehicle. 8. With the engine OFF, gradually apply the
brake pedal approximately 2/3 of its travel distance. 9. Slowly release the brake pedal.
10. Wait 15 seconds then repeat steps 8-9 until a firm brake pedal is obtained. This will properly
seat the brake caliper pistons and the brake pads. 11. Fill the master cylinder reservoir to the
proper level. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master
Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling).
12. Burnish the brake pads and rotors. Refer to Brake Pad and Rotor Burnishing (See: Brake Pad
and Rotor Burnishing).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Brake Pads Replacement > Page 6375
Brake Pad: Service and Repair Brake Pad and Rotor Burnishing
Brake Pad and Rotor Burnishing
Warning
Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any
maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead
to serious personal injury and vehicle damage.
Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking
surfaces are properly prepared after service has been performed on the disc brake system.
This procedure should be performed whenever the disc brake rotors have been refinished or
replaced, and/or whenever the disc brake pads have been replaced.
1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph).
Note: Use care to avoid overheating the brakes while performing this step.
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the
brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow
sufficient cooling periods between stops in order to properly
burnish the brake pads and rotors.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures
Technical Service Bulletin # 00-05-22-002L Date: 090326
Brakes- Disc Brake Warranty Service And Procedures
INFORMATION
Bulletin No.: 00-05-22-002L
Date: March 26, 2009
Subject: Disc Brake Warranty Service and Procedures
Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2
2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X
(Canada Only) 1999-2010 Saturn Vehicles (Canada Only)
EXCLUDING 2009-2010 Chevrolet Corvette ZR1
Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake
corner and wheel design, assembly plant build processes and dealership required tools like the
On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing
base brake service. Due to this change, you are no longer required to enter the LRO measurement
on the repair order or in the warranty system failure code section. The bulletin information below
and the base brake labor operations have been updated accordingly. Due to this change it is more
important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration
Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes).
For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service
Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional
information, the Service Technical College lists a complete index of available Brake courses. This
information can be accessed at www.gmtraining.com > resources > training materials > brakes
courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake
Certification program 15003.16H.
Important
PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR
NEXT GM BRAKE SERVICE.
The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a
successful brake service.
1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace
2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel
3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness
(REQUIRED on Repair Order)
Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly
calibrated.
4. Properly reassemble the brake corner using proper torque tools, torque specification and torque
sequence - wheel lug nuts.
* The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after
refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec
after refinish and not the discard spec.
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Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6380
Bulletin Format
***REPAIR ORDER REQUIRED DOCUMENTATION
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Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6381
Important
When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake
Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor
Thickness are required and MUST be written/documented on the repair order, or for your
convenience, complete the form (GM Brake Service Repair Order Documentation for Required
Measurements) shown above and attach it to the repair order. If the Warranty Parts Center
generates a request, this Documentation/Form must be attached to the repair order that is sent
back.
Important
Documentation of brake lathe maintenance and calibration as recommended by the lathe
manufacturer must be available for review upon request.
Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED
When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before
refinish) and REFINISHED thickness (measured thickness after refinish) MUST be
written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is
necessary, only the original thickness measurement needs to be recorded.
Repair Order Documentation - Explanation of Part Replacement - REQUIRED
If replacement of a brake component is necessary, proper documentation on the repair order is
required. See the following examples:
^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a
prior brake service. After rotor measurement, it was determined that refinishing the rotor again
would take it under the Minimum Thickness specification.
^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads
contaminated by fluid leak at caliper.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6382
TOOL INFORMATION
CORRECTION PLATE PART INFORMATION
Refer to TSB 01-05-23-001 for the Brake Align(R) application chart.
For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be
submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are
available through the following suppliers:
- Dealer Equipment and Services
- Brake Align(R) LLC (U.S. Dealers Only)
* We believe this source and their products to be reliable. There may be additional manufacturers
of such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items, which may be available from
other sources.
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Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6383
WARRANTY INFORMATION
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6384
WORKSHEET - BRAKE LATHE CALIBRATION
Important
Brake lathe calibration should be performed and recorded monthly or if you are consistently
measuring high LRO after rotor refinishing.
Disclaimer
GM Brake Service Procedure
GM BRAKE SERVICE PROCEDURE
1. Remove the wheel and caliper.
2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following
steps:
Important
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Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6385
If performing routine Brake Service for worn pads only, and the rotors are not damaged and
measure within specification - DO NOT REFINISH ROTORS.
1. Remove the rotor(s).
2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points
should be taken and the lowest measurement
should be recorded.
3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for
Minimum Thickness specification/other. In
most cases, the rotor should be refinished unless the measurement taken makes it obvious that
refinishing the rotor would take the measurement under the Minimum Thickness specification (then
replacement is necessary). DO NOT use any other manufacturers rotor specifications.
3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as
noted in the "Repair Order Documentation - Rotor
Refinish" section of this bulletin.
4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz
Wheel(R).
If rotors are not to be refinished - Go To Step 8.
Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris
(which includes removal of Hubless rotors) is critical and MUST be performed whether using an
On-Car or Bench Lathe Refinish Procedure.
5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are
using.
Important Only replace the rotors if they do not meet the Minimum Thickness specification.
Important DO NOT REFINISH NEW ROTORS.
Important Only remove the necessary amount of material from each side of the rotor and note that
equal amounts of material do not have to be removed from both sides on any brake system using a
floating caliper.
Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with
the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut.
Bench Type Lathe
1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and
parallel surfaces.
2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of
debris or burrs. For more information, see the
"Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin.
3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake
pad area of the rotor. Feed the cutting tools
into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a
full turn
4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed
during the process, reset zero. Back off a full turn.
5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the
brake pad contact area. Do the same
procedure. If zero is passed during the process, reset zero.
6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the
full rotor surface. Advance both tool cutters to the
zero setting plus just enough to clean up the entire rotor surface.
7. After completing the refinish, sand both sides of the rotor for approximately one minute per side
using a sanding block and 130-150 grit sandpaper
to obtain a non-directional finish.
On-Car Type Lathe
1. Reinstall the rotor(s).
Important
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Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6386
When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is
critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe.
Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating
driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep
their body out of the wheel well area until the machine has reached its normal operating RPM.
2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and
parallel surfaces.
Important When raising the vehicle on the lift, be sure to have it at a good working height (waist
high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the
lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming
out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time
of the lathe.
3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the
vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb
ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the
adapter.
Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor
retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface.
4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for
run-out in the hub.
5. Once the computer indicates the compensation process was successful, on the outboard area of
the rotor, position the cutting tools one eighth
of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the
rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn.
6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed
during the process, reset zero. Back off a full turn.
7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the
brake pad contact area. Do the same
procedure. If zero is passed during the process, reset zero.
8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the
full rotor surface. Advance both tool cutters
to the zero setting plus just enough to clean up the entire rotor surface.
9. After completing the refinish, sand both sides of the rotor for approximately one minute per side
using a sanding block and 130-150 grit
sandpaper to obtain a non-directional finish.
10. Dismount the lathe, but leave the lathe adapter attached to the vehicle.
6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish
washing soap) or wipe it clean with GM approved
brake cleaner, P/N 88862650 (Canadian P/N 88901247).
Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as
a by-product of machining to the pad material during the seating process, thus reducing the
opportunity for squeaks or other noises to occur.
7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer
to the "Repair Order Documentation - Rotor
Refinish" section of this bulletin.
8. Setting up to measure for Lateral Run Out (LRO):
Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these
steps are being left in the overall procedure as a good check to be performed in the case of a
repeat pulsation complaint. If you are not checking for LRO, go to step 16.
Bench-Type Lathe
1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean
and free of debris.
2. Mount the new, original or refinished rotor onto the vehicle hub.
Important Always hold the rotor on the bottom half so any debris that may be dislodged from the
vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor
falling over on the studs can release rust from the vents on the rotor.
3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto
the studs.
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Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6387
4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical
washers (with the tapered hole side facing
out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it.
5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start
and snug the lug nuts by hand.
6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with
the lug nut opposite of the one you first
tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not
completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the
lug nuts in a star pattern to the specific vehicle torque specification.
7. DO NOT reinstall the caliper or the wheel at this time.
On-Car Type Lathe
1. Leave the On-Car adapter on the wheel.
2. Proceed to Step 9.
9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor
outboard friction surface approximately 6.35 mm
(0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of
the rotor.
Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false
readings.
10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification
(0.050 mm (0.002 in) or LESS).
1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is
indicated and set the dial indicator to zero.
2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading
(rotor "high spot"). Note the amount and mark
the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location.
If the high point falls between two studs, mark both studs. In instances where the vehicle has
"capped lug nuts" you should mark the hub.
11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is
necessary. Go to Step 15 if this is the first rotor
completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050
mm (0.002 in), go to Step 12.
12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to
correct for LRO:
Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of
the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of
LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure").
Hubless Rotor
1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B),
choose the correct plate to bring the rotor
LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006
in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the
instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B.
2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high
spot") or between the two points marked (if
the "high spot" is between two wheel studs).
Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer
to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO.
Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates
together on one hub. NEVER attempt to reuse a previously installed Correction Plate.
3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8.
Make sure to index the rotor correctly to the
marks made in step 10, otherwise LRO will be comprised.
Hubbed / Captured / Trapped Rotor
1. Measure the rotor thickness.
2. Refinish or replace the rotor (see Service Information for further details).
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Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6388
13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification.
14. If using,
BENCH LATHE - DO NOT remove conical washers and lug nuts at this time.
ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain
rotor position.
Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the
hub and install the top conical washer and lug nut first to ensure no debris falls between the
surface while removing the adapter. Then, install the remaining conical washers and lug nuts.
Otherwise, LRO will be comprised.
15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO).
16. Reinstall the rotors on both sides of the vehicle and perform the following steps:
1. Reinstall the calipers and pads.
2. Pump the brakes to pressurize the calipers.
3. Remove the lug nuts/conical washers.
4. Install and properly torque the wheels.
Important It is critical to follow the star pattern wheel torque procedure and use the proper tools
(torque stick or torque wrench) as referenced in SI.
17. Road test the vehicle to verify the repairs.
Brake Lathe Calibration Procedure
BRAKE LATHE CALIBRATION PROCEDURE
Calibration of the brake lathe should be performed and recorded monthly or whenever post-service
brake rotor LRO measurements are consistently reading above specification.
BENCH-TYPE LATHE
Use the following procedure to calibrate a Bench-type brake lathe:
1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it
from rotating, rotate the rotor 180 degrees.
2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as
checking the run out on the vehicle.
3. Rotate the arbor and read the runout.
4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the
rotor.
Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe
(this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an
On-Car type lathe).
Machining the Inside Bell Clamp (Bench Type Lathe Only)
Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to
accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat
against the shoulder surface using slight pressure. When the burrs are gone, clean the surface.
Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with
the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing
the burrs, clean the hub.
Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then
spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool
bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the
face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360
degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and
line up these marks before machining a rotor. A magic marker can be used to make the match
marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell
Clamps used.
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Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6389
Important
If runout is still present, contact the brake lathe supplier.
ON-CAR TYPE LATHE
Use the following procedure to calibrate an On-Car brake lathe:
1. Connect the lathe to a vehicle using the appropriate adapter.
2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a
flat surface on the cutting head.
3. Turn on the lathe and press the "start" button so the lathe begins to compensate.
4. Once compensation is complete, note the runout as measured by the dial indicator. Measured
runout at this point is overstated given that it is
outside the rotor diameter.
5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor
diameter), calibration must be tightened. Follow
manufacturer's instructions for tightening the calibration of the lathe. This information is found in the
manual supplied with the lathe.
Important If the machine is taking a long time to compensate during normal use, prior to checking
the lathe calibration, it is recommended that the machine be disconnected from the adapter and the
adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will
accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will
change the location of the runout (phase) relative to the machine and thus possibly allow for quick
compensation as a result of the position change.
The following information has been added as a reference to ensure your Pro-Cut PFM lathe
provides a consistent smooth surface finish over long term usage.
Cutting Tips / Depth of Cut / Tip Life
The cutting tips must be right side up. Reference marks always face up. The cutting tips may not
have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will
provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits,
make sure that the seat area for the tip on the tool is free and clear of debris.
Cutting Head
On each brake job, the technician must center the cutting head for that particular vehicle using one
of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the
technician use one hand to push the head firmly and squarely back into the dovetail on the slide
plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do
this could result in chatter occurring during the cut.
Tool Holder Plate (Cutting Head)
The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a
technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts
of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not
cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder
plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head
from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder
plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide
plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting
arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will
show itself by having the back of the cutting arm lifting off the surface of the tool holder.
Gib Adjustment / Loose Gib
As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do
this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment
process, which you should perform when required after monthly checks or whenever surface finish
is inconsistent.
Brake Pulsation
BRAKE PULSATION
Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes
the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The
"pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may
result from two basic conditions:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6390
1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner
assembly is virtually undetectable unless measured
(with a dial indicator after the brake service) and will not be detected as brake pulsation during an
after brake service test drive. If the brake corner is assembled with excessive LRO (greater than
0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles.
Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor
thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in
4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will
develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts).
Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the
cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the
service event for the condition to develop. The customer does not usually make the connection
between the service event and the awareness of the pulsation. The proper usage of torque
wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation
conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly
increases the likelihood of pulsation after wheel service.
The following are examples of pulsation conditions and reimbursement recommendations:
- If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually
got worse, normally the repair would be covered. The customer may tolerate the condition until it
becomes very apparent.
- If a GM dealer performed a prior brake service, consider paying for the repair and then strongly
reinforce proper brake lathe maintenance.
- If the customer had the brake service done outside of a GM dealership, normally GM would not
offer any assistance.
- If a customer indicated they had wheel service, ask who performed the service. Then;
- If a GM dealer performed the service, consider paying for the repair and then strongly reinforce
the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM
products. Each technician needs to use torque sticks properly every time the wheel nuts are
tightened.
- If the customer had the wheel service done outside of a GM dealership, normally GM would not
offer any assistance.
2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another
form of thickness variation, which can cause a
pulsation concern and can be addressed as follows:
- Cosmetic Corrosion:
In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary.
- Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi):
At times more extensive corrosion can cause pulsation due to thickness variation. This usually
happens when the vehicle is parked for long periods of time in humid type conditions and the
braking surface area under the pads corrodes at a different rate compared to the rest of the braking
surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15
moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple
moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure"
below.
- Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi):
In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and
miles can cause the same type of pulsation complaint due to thickness variation. In these cases,
the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against
the darker surface. This darker surface is usually due to build-up, on the rotor material surface,
caused by a combination of corrosion, pad material and heat. To correct this condition, follow the
"Brake Rotor Clean-up Procedure" below.
- Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 +
km (5,000 + miles) :
At times, more extensive corrosion over time and miles can cause pulsation due to thickness
variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by
a combination of corrosion, pad material and heat. When rotor measurements are taken, the low
areas are usually close to the original rotor thickness (new rotor) measurement and the high areas
usually measure more than the original rotor thickness (new rotor) measurement (depending on
mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure"
described below.
Important In some flaking instances, cleaning-up this type of corrosion may require more rotor
material to be removed then desired. Customer consideration should be taken in these situations
and handled on a case by case basis, depending on the amount/percentage of rotor life remaining
and the vehicle's warranty time and miles.
Brake Rotor Clean-Up Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6391
BRAKE ROTOR CLEAN-UP PROCEDURE
Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and
parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is
clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure"
section in this bulletin.
1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake
pad area of the rotor. Feed the cutting tools into the
rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn.
2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed
during the process, reset zero. Back off a full turn.
3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the
brake pad contact area. Do the same procedure. If
zero is passed during the process, reset zero.
4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the
full rotor surface. Advance both tool cutters to the
zero setting plus just enough to clean up the entire rotor surface.
5. After completing the refinish, sand both sides of the rotor for approximately one minute per side
using a sanding block and 130-150 grit sandpaper
to obtain a non-directional finish.
Important Only remove the necessary amount of material from each side of the rotor and note that
equal amounts of material do not have to be removed from both sides on any brake system using a
floating caliper.
Important In many of these instances, such a minimal amount of material is removed from the rotor
that customer satisfaction is not a concern for future brake services. This procedure is intended to
"Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut",
"refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor
material/life. If the brake lathe equipment being used is not capable of removing minor amounts of
material while holding tolerances, further lathe maintenance, repair, updates or equipment
replacement may be necessary.
Brake Noise
BRAKE NOISE
Some brake noise is normal and differences in loading, type of driving, or driving style can make a
difference in brake wear on the same make and model. Depending on weather conditions, driving
patterns and the local environment, brake noise may become more or less apparent. Verify all
metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and
lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a
"slip-stick" vibration of brake components. While intermittent brake noise may be normal,
performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the
noise persists and is consistently occurring, a brake dampening compound may be applied to the
back of each pad. This allows parts to slide freely and not vibrate when moving relative to each
other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or
equivalent.
The following noises are characteristics of all braking systems and are unavoidable. They may not
indicate improper operation of the brake system.
Squeak/Squeal Noise:
- Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is
applied to the brake pedal.
- Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes
and/or high humidity.
Grinding Noise:
- Common to rear brakes and some front disc brakes during initial stops after the vehicle has been
parked overnight.
- Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few
stops.
Groan Noise:
A groan type noise may be heard when stopping quickly or moving forward slowly from a complete
stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard
braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS
activation.
Key Points - Frequently Asked Questions
KEY POINTS - FREQUENTLY ASKED QUESTIONS
- Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor,
either surface finish or LRO?
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6392
A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the
dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no
difference in the cutting/surface finish and LRO are just the same as with a non-floating axle.
- Q: Which lathe is essential for performing brake work, the bench or on-car?
A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These
lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality
brake service.
- Q: What is the expected tip life for an on-car lathe?
A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When
using the Pro-Cut the cutting depth should be set to take all material needed to get below rust
grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381
mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or
"finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last
between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts.
- Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and
on-car brake lathes?
A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant
number of bench and on-car brake lathes. These tests measured critical performance
characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over
many uses. In each test, single pass lathe designs out performed the competitors. Single pass
brake lathes are more productive requiring less time to perform the same procedure.
- Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe?
A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The
debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other
brake concerns and comebacks.
- Q: What information needs to be documented on the Repair Order?
A: Any claim that is submitted using the labor operations in this bulletin, must have the Original
Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For
more information, refer to the "Repair Order Required Documentation" section of this bulletin.
All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited
where the repair does not comply with this procedure.
Brake Warranty
BRAKE WARRANTY
Brake Rotors:
- Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty.
Reference the vehicle's warranty guide for verification.
- Rotors should not be refinished or replaced during normal/routine pad replacement.
- Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type
noises and/or premature lining wear out.
- Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces
can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time
between stops.
- Rotors should not be refinished or replaced for rotor discoloration/hard spots.
- Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a
result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or
corrosion (Lot Rot).
- When rotor refinishing, only remove the necessary amount of material from each side of the rotor
and note that equal amounts of material do not have to be removed from both sides on any brake
system using a floating caliper.
- Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in).
Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should
be replaced.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6393
- It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However,
caution should be exercised, as a variance in surface finish may cause a brake pull condition.
- New rotors should not be refinished before installation. Original equipment rotor surfaces are
ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new
rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the
hub, correct it using one of the following methods:
1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service
Procedure for Hubless Rotors" outlined in this
bulletin.
2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the
procedure outlined in this bulletin.
- Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the
rotor should be replaced.
Important If the Minimum Thickness specification is not visible on the rotor, reference Service
Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor
specifications.
Brake Pads:
Important When determining the warranty coverage (as an example) - if all four front or four rear
brake pads are excessively worn evenly, that would NOT be covered under warranty since this
type of wear is most likely due to driving habits or trailering. However, if the brake pads are
excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration
should be given to cover this under warranty since this type of wear is most likely due to poor
operation of other braking components.
- Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding
owner abuse, excessive trailering, or the situations that would not be considered normal use).
- Installation of new rotors does not require pad replacement. Do not replace pads unless their
condition requires it - excessively worn, damage or contaminated.
Brake Wear:
Several factors impact brake lining wear and should be taken into account when reviewing related
issues:
- heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving /
driver braking characteristics (left foot or two feet)
The following are conditions that may extend brake lining wear:
- light loads / highway driving / conservative driving / level terrain
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Page 6394
Brake Rotor/Disc: Specifications
BRAKE ROTOR/DISC
Brake Rotor Discard Thickness............................................................................................................
........................................................27.5 mm (1.08 in) Brake Rotor Maximum Allowable Thickness
Variation...........................................................................................................................0.050 mm
(0.002 in) Lateral Runout......................................................................................................................
....................................................................0.125 mm (0.005 in)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Surface and Wear Inspection
Brake Rotor/Disc: Testing and Inspection Brake Rotor Surface and Wear Inspection
Brake Rotor Surface and Wear Inspection Warning: Refer to Brake Dust Warning (See: Service
Precautions/Technician Safety Information/Brake Dust Warning).
1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the
caliper with the brake pads. Refer to Brake Pads
Replacement (See: Brake Pad/Service and Repair/Brake Pads Replacement).
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved
brake cleaner. 3. Inspect the friction surfaces of the brake rotor for the following Braking Surface
Conditions:
* Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc. Heavy surface
rust and/or pitting must be removed by refinishing the rotor.
* Cracks and/or heat spots
* Excessive blueing discoloration
4. If the friction surfaces of the brake rotor exhibit one or more of the Braking Surface Conditions,
the rotor requires refinishing or replacement.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Surface and Wear Inspection > Page 6397
Brake Rotor/Disc: Testing and Inspection Brake Rotor Thickness Measurement
Brake Rotor Thickness Measurement Warning: Refer to Brake Dust Warning (See: Service
Precautions/Technician Safety Information/Brake Dust Warning).
1. Clean the brake pad lining contact surface of the brake rotor with denatured alcohol or an
equivalent brake cleaner. 2. Using a micrometer calibrated in ten-thousands of an inch, measure
and record the lowest thickness of the brake rotor at 4 or more points, equally
spaced around the rotor. Ensure that the measurements are only taken within the brake pad lining
contact area and that the micrometer is positioned the same distance from the outside edge of the
rotor for each measurement.
3. Compare the lowest thickness measurement recorded to the following specifications:
Brake rotor discard thickness 27.5 mm (1.08 in).
4. If the lowest thickness measurement of the brake rotor is above the brake rotor discard thickness
specification; the rotor may be able to be
refinished, depending upon surface and wear conditions which may be present.
5. If the lowest thickness measurement of the brake rotor is at or below the discard thickness
specification; the rotor requires replacement.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures
Brake Rotor/Disc: Procedures
Brake Rotor Refinishing
Special Tools
CH-47661 On-Vehicle Brake Lathe
Note: Do NOT refinish the brake rotors in order to correct any of the following complaints:
* Growl or squeal brake noise
* Premature brake lining wear
* Cosmetic or superficial corrosion of the rotor braking surface
* Rotor discoloration
Refinish the brake rotors ONLY when 1 or more of the following conditions exist:
* Groove depth in excess of specification
* Severe scoring of the rotor braking surface
* Brake pulsation caused by the following:
- Lateral runout in excess of specification
- Brake rotor thickness variation in excess of specification
- Corrosion or pitting that is deeper than the rotor braking surface
1. Use a micrometer in order to measure the thinnest point of the brake rotor. If the thinnest point of
the brake rotor exceeds the brake rotor minimum
thickness, do NOT refinish the brake rotor. Replace the brake rotor.
2. Use the CH-47661 to refinish the brake rotor. Refer to the brake lathe manufacturer's operating
instructions.
Note: Failure to obtain the best possible braking surface finish may cause the vehicle to stop with
difficulty.
3. After machining the rotor, use 120 grit aluminum oxide sandpaper and a non-directional rotor
finisher, if available, in order to create a
non-directional braking surface.
4. Clean the braking surfaces with GM P/N 12377981 (Canadian P/N 10953463) or equivalent,
brake parts cleaner.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures > Page 6400
Brake Rotor/Disc: Removal and Replacement
Brake Pad and Rotor Burnishing
Brake Pad and Rotor Burnishing
Warning
Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any
maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead
to serious personal injury and vehicle damage.
Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking
surfaces are properly prepared after service has been performed on the disc brake system.
This procedure should be performed whenever the disc brake rotors have been refinished or
replaced, and/or whenever the disc brake pads have been replaced.
1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph).
Note: Use care to avoid overheating the brakes while performing this step.
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the
brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow
sufficient cooling periods between stops in order to properly
burnish the brake pads and rotors.
Brake Rotor Replacement
Brake Rotor Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair
).
3. Remove the wheel bearing and hub assembly. Refer to Front Wheel Bearing and Hub
Replacement (See: Maintenance/Wheels and Tires/Wheel
Bearing/Service and Repair).
Note: Support the brake rotor assembly on wooden blocks to prevent damage to brake rotor friction
surface.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures > Page 6401
4. While supporting the brake rotor assembly, remove the 6 wheel hub bolts.
5. Separate the wheel hub from the brake rotor. 6. Clean the wheel hub and brake rotor mating
surfaces to remove any debris or corrosion.
Installation Procedure
Note: Support the brake rotor assembly on wooden blocks to prevent damage to brake rotor friction
surface.
1. Position the wheel hub to the brake rotor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: Use only hand tools to install the wheel hub bolts.
Note: Ensure the wheel hub and brake rotor are properly mated.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures > Page 6402
2. While supporting the brake rotor assembly, install the 6 wheel hub bolts and, using only hand
tools, tighten the bolts to 120 Nm (89 lb ft). 3. Install the wheel bearing and hub assembly. Refer to
Front Wheel Bearing and Hub Replacement (See: Maintenance/Wheels and Tires/Wheel
Bearing/Service and Repair).
4. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component
Information > Service and Repair
Backing Plate: Service and Repair
Rear Brake Backing Plate Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear wheel speed sensor. Refer to
Rear Wheel Speed Sensor Replacement (See: Antilock Brakes / Traction Control Systems/Wheel
Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement).
3. Remove the park brake cable from the rear brake backing plate. Refer to Parking Brake Rear
Cable Replacement - Left Side (See: Parking Brake
System/Parking Brake Cable/Service and Repair/Removal and Replacement/Parking Brake Rear
Cable Replacement - Left Side) or Parking Brake Rear Cable Replacement - Right Side (See:
Parking Brake System/Parking Brake Cable/Service and Repair/Removal and
Replacement/Parking Brake Rear Cable Replacement - Right Side).
4. Remove the wheel cylinder. Refer to Wheel Cylinder Replacement (See: Wheel Cylinder/Service
and Repair). 5. Remove the rear axle shaft. Refer to Rear Axle Shaft Replacement (See:
Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle
Shaft Assembly/Axle Shaft/Service and Repair).
6. Remove the rear brake backing plate bolts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component
Information > Service and Repair > Page 6407
7. Remove the rear brake backing plate (1).
Installation Procedure
1. Install the rear brake backing plate (1).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component
Information > Service and Repair > Page 6408
2. Install the rear brake backing plate bolts (1) and tighten to 135 Nm (100 lb ft). 3. Install the rear
axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles,
Bearings and Joints/Axle Shaft
Assembly/Axle Shaft/Service and Repair).
4. Install the wheel cylinder. Refer to Wheel Cylinder Replacement (See: Wheel Cylinder/Service
and Repair). 5. Install the park brake cable to the rear brake backing plate. Refer to Parking Brake
Rear Cable Replacement - Left Side (See: Parking Brake
System/Parking Brake Cable/Service and Repair/Removal and Replacement/Parking Brake Rear
Cable Replacement - Left Side) or Parking Brake Rear Cable Replacement - Right Side (See:
Parking Brake System/Parking Brake Cable/Service and Repair/Removal and
Replacement/Parking Brake Rear Cable Replacement - Right Side).
6. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See:
Antilock Brakes / Traction Control Systems/Wheel
Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information
> Specifications
Brake Drum: Specifications
BRAKE DRUM
Maximum Allowable Diameter..............................................................................................................
................................................296.5 mm (11.673 in) Maximum Allowable Radial Runout...................
.......................................................................................................................................0.15 mm
(0.006 in)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information
> Testing and Inspection > Brake Drum Diameter Measurement
Brake Drum: Testing and Inspection Brake Drum Diameter Measurement
Brake Drum Diameter Measurement
1. Clean the brake shoe lining contact surface of the brake drum with denatured alcohol or an
equivalent brake cleaner. 2. Using a brake drum micrometer calibrated in thousands of an inch,
measure and record the largest diameter of the brake drum at 4 or more points,
equally spaced around the drum. Ensure that the measurements are only taken within the brake
shoe lining contact area and that the micrometer is positioned the same distance from the outside
edge of the drum for each measurement.
3. The maximum allowable diameter :
Maximum allowable measurement 296.5 mm (11.673 in)
4. If the largest diameter measurement of the brake drum is less than the maximum allowable
diameter, the drum may be able to be resurfaced,
depending upon surface and wear conditions which may be present.
5. If the largest diameter measurement of the brake drum is equal to or greater than the maximum
allowable measurement, the drum requires
replacement.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information
> Testing and Inspection > Brake Drum Diameter Measurement > Page 6414
Brake Drum: Testing and Inspection Brake Drum Surface and Wear Inspection
Brake Drum Surface and Wear Inspection
Special Tools
J 8001 Dial Indicator Set, or equivalent
Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety
Information/Brake Dust Warning).
1. With the brake drum removed, clean the braking (friction) surface of the brake drum with
denatured alcohol or an equivalent approved brake
cleaner.
2. Inspect the braking surface of the brake drum for the following Braking Surface Conditions:
* Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc; heavy surface
rust and/or pitting must be removed by refinishing the drum.
* Cracks and/or heat spots
* Excessive blueing discoloration
* Missing balance weights
3. If the braking surface of the brake drum exhibits one or more of the Braking Surface Conditions,
the drum requires refinishing or replacement.
4. Using a brake drum micrometer calibrated in thousands of an inch, measure and record any
grooves present on the drum braking surface.
Ensure that the measurements are only taken within the brake shoe lining contact area.
5. Compare the groove, scoring, depth recorded to the following specification:
Brake drum maximum allowable scoring 1.5 mm (0.06 in).
6. If the brake drum scoring depth exceeds the specification, or if an excessive amount of scoring is
present, the drum requires refinishing or
replacement.
7. Mount the brake drum on a brake lathe. 8. Mount a dial indicator, J 8001 or equivalent, and
position the indicator button so it contacts the braking surface of the brake drum at a 90 degree
angle, approximately 19 mm (0.75 in) from the drum's outer edge.
9. Measure and record the radial runout of the brake drum.
1. Rotate the drum until the lowest reading is displayed on the indicator dial, then zero the dial. 2.
Rotate the drum until the highest reading is displayed on the dial.
10. Compare the radial runout of the brake drum to the following specification:
Brake drum maximum allowable radial runout 0.15 mm (0.006 in).
11. If the brake drum radial runout exceeds the specification, the drum requires refinishing or
replacement.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information
> Service and Repair > Procedures
Brake Drum: Procedures
Brake Drum Refinishing
Tools Required
J 41013 Rotor Resurfacing Kit
Important: Do NOT refinish the brake drums in order to correct any of the following complaints:
* Brake noise (growl/squeal)
* Premature brake lining wear
* Cosmetic or superficial corrosion of the drum braking surface
* Drum discoloration
Refinish the brake drums ONLY when 1 or more of the following conditions exist:
* Severe scoring of the drum braking surface (groove depth in excess of specification)
* Brake pulsation caused by the following:
- Brake drum out of round (runout in excess of specification)
- Corrosion or pitting that is deeper than the drum braking surface
1. Use a micrometer in order to measure the largest diameter of the brake drum. If the largest
diameter of the brake drum exceeds the brake drum
maximum refinish diameter, do NOT refinish the brake drum. Replace the brake drum.
2. Use the J 41013 or an equivalent tool in order to THOROUGHLY clean the rust from the brake
drum flange. 3. Refinish the brake drum. Refer to the brake lathe manufacturer's operating
instructions.
Important: Failure to obtain the best possible braking surface finish may cause the vehicle to stop
with difficulty.
4. After machining the brake drum, use 120 grit aluminum oxide sandpaper in order to create a
non-directional braking surface. 5. Clean the braking surfaces with GM P/N 12377981 (Canadian
P/N 10953463) or equivalent brake parts cleaner.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information
> Service and Repair > Procedures > Page 6417
Brake Drum: Removal and Replacement
Brake Drum Replacement
Special Tools
J-42450-A - Wheel Hub Resurfacing Kit
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair
).
3. Remove and discard the brake drum retainers (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information
> Service and Repair > Procedures > Page 6418
4. Remove the brake drum (1). 5. If the brake drum is difficult to remove, retract the brake shoes
using the following procedure:
1. Remove the rubber adjuster access hole plug located below the wheel cylinder on the rear brake
backing plate. 2. Insert a small, flat bladed tool through the access hole at a slight downward angle
to contact the adjuster lever. 3. Insert a second small, flat bladed tool straight into the access hole
just above the first tool to contact the adjuster teeth. 4. While applying slight inward pressure on the
first tool, rotate the adjuster counter clockwise using the second tool against the adjuster teeth. 5.
Continue to rotate the adjuster until the brake shoes are retracted and the brake drum can be
removed.
6. Using the J-42450-A - Wheel Hub Resurfacing Kit , clean the brake drum and rear axle flange
mating surfaces of any accumulated dirt or
corrosion.
Installation Procedure
1. Adjust the rear drum brakes. Refer to Drum Brake Adjustment (See: Adjustments).
2. Install the brake drum (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information
> Service and Repair > Procedures > Page 6419
3. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information
> Specifications
Brake Shoe: Specifications
BRAKE SHOE
Bonded Lining.......................................................................................................................................
.....................................................0.72 mm (0.028 in) Riveted Shoe ...................................................
....................................................................................................................................... 0.76 mm
(0.029 in)*
*Replace riveted shoe and lining assemblies when the lining is worn to within 0.76 mm (0.029 in) of
any rivet head.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information
> Specifications > Page 6423
Brake Shoe: Testing and Inspection
Brake Shoe Inspection
Inspect the linings every 9,650 km (6,000 mi) and any time the wheels are removed (tire rotation,
etc.). Inspect the lining for wear by removing the brake drum. Replace the shoe and lining
assemblies when the thickness of any lining is worn within 0.72 mm (0.030 in) of the shoe. Replace
riveted shoe and lining assemblies when the lining is worn to within 0.76 mm (0.030 in) of any rivet
head. Always replace shoe and lining assemblies as a complete axle set.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information
> Specifications > Page 6424
Brake Shoe: Service and Repair
Brake Shoe Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
1. Remove the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and
Repair/Removal and Replacement).
2. Remove the brake shoe adjuster spring (1).
3. Remove the brake shoe adjuster lever (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information
> Specifications > Page 6425
4. Carefully spread the top of the brake shoes away from the wheel cylinder and remove the brake
shoe adjuster assembly (1).
5. Remove the brake shoe hold down springs and cups by compressing the springs inward and
rotating the cups 1/4 turn.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information
> Specifications > Page 6426
6. Rotate the forward brake shoe (1) toward the rear axle flange. 7. Remove the brake shoe lower
retaining spring (2).
8. Remove the forward brake shoe (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information
> Specifications > Page 6427
9. Remove the brake shoe upper return spring (1).
10. Release the park brake cable fitting from the brake shoe park brake apply lever. 11. Remove
the rear brake shoe and park brake lever assembly (2)
Installation Procedure
1. Clean the rear brake backing plate brake shoe contact points. 2. Apply a light coat of high
temperature silicone brake lubricant to the rear brake backing plate brake shoe contact points.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information
> Specifications > Page 6428
3. Install the park brake cable fitting to the brake shoe park brake apply lever.
4. Install the brake shoe upper return spring (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information
> Specifications > Page 6429
5. Install the forward brake shoe (1).
6. Rotate the forward brake shoe (1) toward the rear axle flange. 7. Install the brake shoe lower
retaining spring (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information
> Specifications > Page 6430
8. Install the brake shoe hold down springs and cups by compressing the springs inward and
rotating the cups 1/4 turn.
9. Carefully spread the top of the brake shoes away from the wheel cylinder and install the brake
shoe adjuster assembly (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information
> Specifications > Page 6431
10. Install the brake shoe adjuster lever (1).
11. Install the brake shoe adjuster spring (1). 12. Adjust the rear brake shoes. Refer to Drum Brake
Adjustment (See: Adjustments). 13. Install the brake drum. Refer to Brake Drum Replacement
(See: Brake Drum/Service and Repair/Removal and Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair
Wheel Cylinder: Service and Repair
Wheel Cylinder Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
1. Remove the rear brake shoes. Refer to Brake Shoe Replacement (See: Brake Shoe/Service and
Repair).
2. Disconnect the brake pipe fitting (1) from the wheel cylinder.
Cap the brake pipe fitting and plug the wheel cylinder inlet port to prevent brake fluid loss and
contamination.
3. Remove the wheel cylinder bolts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Page 6435
4. Remove the wheel cylinder (1).
Installation Procedure
1. Install the wheel cylinder (1).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Page 6436
2. Install the wheel cylinder bolts (1) and tighten to 18 Nm (13 lb ft).
3. Connect the brake pipe fitting (1) to the wheel cylinder and tighten to 19 Nm (14 lb ft). 4. Install
the rear brake shoes. Refer to Brake Shoe Replacement (See: Brake Shoe/Service and Repair). 5.
Bleed the wheel cylinder. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake
Bleeding/Service and Repair)Hydraulic Brake
System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes Brake Pedal Spongy/Increased Pedal Travel
Brake Bleeding: Customer Interest Brakes - Brake Pedal Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes Brake Pedal Spongy/Increased Pedal Travel > Page 6446
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes Brake Pedal Spongy/Increased Pedal Travel > Page 6447
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 >
Brakes - Brake Pedal Spongy/Increased Pedal Travel
Brake Bleeding: All Technical Service Bulletins Brakes - Brake Pedal Spongy/Increased Pedal
Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 >
Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 6453
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 >
Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 6454
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6455
Brake Bleeding: By Symptom
Technical Service Bulletin # 09-05-25-003 Date: 090921
Brakes - Brake Pedal Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6456
List of Affected Units
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6457
Disclaimer
Technical Service Bulletin # 09-05-25-003 Date: 090921
Brakes - Brake Pedal Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6458
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6459
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 09-05-25-003 Date: 090921
Brakes - Brake Pedal Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6460
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6461
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure
Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure
Antilock Brake System Automated Bleed Procedure
Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
Note: The base hydraulic brake system must be bled before performing this automated bleeding
procedure. If you have not yet performed the base hydraulic brake system bleeding procedure,
refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding
(Pressure) ( See: ) before proceeding.
1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the
brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the
automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated
bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF.
7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the
maximum-fill level with Delco Supreme 11(R) GM P/N 12377967 (Canadian P/N 992667) or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See:
)Hydraulic Brake System Bleeding (Pressure) (
See: ).
10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in
order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal.
Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated
bleeding procedure. If the brake pedal still feels spongy after repeating the automated
bleeding procedure inspect the brake system for external leaks. Refer to Brake System External
Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake
System External Leak Inspection).
13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp
remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the
vehicle to be driven until it is diagnosed and repaired. Refer to
Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic
Procedures/Symptoms - Hydraulic Brakes).
15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake
pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a
firm brake pedal is obtained.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6464
Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding
Manual
Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See:
Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With
the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, you
must perform the following steps:
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add
GM approved brake fluid from a clean,
sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (See:
Maintenance/Service Intervals). If removal of the reservoir cap and diaphragm is necessary, clean
the outside of the reservoir on and around the cap prior to removal.
2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
brake pipe from the front port of the brake
master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4.
Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant
slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the
same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe,
then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps
3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe
installed securely to the master cylinder, after all air has been purged from the front port of the
master cylinder,
loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8.
10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake
pipe-to-master cylinder fittings are properly
tightened.
4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake
fluid container. Refer to Master Cylinder
Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder
Reservoir Filling). Ensure that the brake master cylinder reservoir remains at least half-full during
this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the
reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6.
Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the
transparent hose into a transparent container partially filled with GM approved brake fluid from a
clean, sealed
brake fluid container. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service
Intervals).
8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the
pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit.
10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15
seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12.
With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been
purged from the right rear hydraulic circuit install
a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With
the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left
rear hydraulic circuit, install a proper
box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With
the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the right front hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly
tightened.
19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid
from a clean, sealed brake fluid container. Refer
to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and
Repair/Procedures/Master Cylinder Reservoir Filling).
20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the
brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy
after repeating the bleeding procedure,
perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Testing and Inspection/Component Tests
and General Diagnostics/Brake System External Leak Inspection).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6465
2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in
the system.
22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven
until it is diagnosed and repaired.
23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes
(See: Testing and Inspection/Symptom Related
Diagnostic Procedures/Symptoms - Hydraulic Brakes).
Pressure
Hydraulic Brake System Bleeding (Pressure)
Special Tools
* J-29532 - Diaphragm Pressure Bleeder, or equivalent
* J-35589-A - Brake Pressure Bleeder Adapter
Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety
Information/Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With
the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, you
must perform the following steps:
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add
GM approved brake fluid from a clean,
sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brake Master
Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). If removal of the
reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap
prior to removal.
2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
brake pipe from the front port of the brake
master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4.
Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant
slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the
same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe,
then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps
3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe
installed securely to the master cylinder, after all air has been purged from the front port of the
master cylinder,
loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8.
10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake
pipe-to-master cylinder fittings are properly
tightened.
4. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid
from a clean, sealed brake fluid container.
Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and
diaphragm.
5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6.
Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or
equivalent. Add GM approved brake fluid from a
clean, sealed brake fluid container as necessary to bring the level to approximately the half-full
point.
7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, to the
J-35589-A - Brake Pressure Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Pressure
Bleeder, or equivalent , or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 Diaphragm Pressure Bleeder, or equivalent , or equivalent, fluid tank valve to allow pressurized
brake fluid to enter the brake
system.
10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to
ensure that there are no existing external brake fluid
leaks. Any brake fluid leaks identified require repair prior to completing this procedure.
11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the
transparent hose into a transparent container partially filled with GM approved brake fluid from a
clean, sealed
brake fluid container.
14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air
bubbles stop flowing from the bleeder, then
tighten the bleeder valve.
15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been
purged from the right rear hydraulic circuit,
install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6466
16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With
the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the left rear hydraulic circuit, install a
proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With
the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the right front hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly
tightened.
22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, fluid tank valve,
then disconnect the J-29532 - Diaphragm
Pressure Bleeder, or equivalent , or equivalent, from the J-35589-A - Brake Pressure Bleeder
Adapter.
23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder
reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved
brake fluid from a clean, sealed brake fluid container. Refer
to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and
Repair/Procedures/Master Cylinder Reservoir Filling)
25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the
brake pedal feels spongy perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Testing and Inspection/Component Tests
and General Diagnostics/Brake System External Leak Inspection).
2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove
any air that may have been trapped in the brake
pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed Procedure
(See: ).
27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven
until it is diagnosed and repaired.
28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes
(See: Testing and Inspection/Symptom Related
Diagnostic Procedures/Symptoms - Hydraulic Brakes).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6467
Brake Bleeding: Service and Repair Hydraulic Brake System Flushing
Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Service
Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
* Fluid separation, indicating two types of fluid are present; a substance other than the
recommended brake fluid has been introduced into the brake hydraulic system
- Swirled appearance - oil-based substance
- Layered appearance - silicone-based substance
* Fluid discoloration, indicating the presence of moisture or particles that have been introduced into
the brake hydraulic system
- Cloudy appearance - moisture
- Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating brake fluid
contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated
by fluid separation and/or a swollen master
cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform
the following:
1. Remove ALL of the following components listed from the vehicle. Each component contains
internal rubber seals/linings which have been
contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the
procedures indicated:
* Master Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and
Replacement/Master Cylinder Replacement)
* Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose
Replacement)
* Rear Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Rear Brake Hose
Replacement)
* Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Brake Caliper Replacement)
* Wheel Cylinder Replacement (See: Wheel Cylinder/Service and Repair)
* Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock
Brakes/Service and Repair)
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake
pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed
and install them to the vehicle. Each component contains internal rubber
seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic
system. Refer to the procedures indicated:
* Master Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and
Replacement/Master Cylinder Replacement) ; also perform the following: Clean the brake master
cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using
non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary.
Refer to Master Cylinder Reservoir Replacement (See: Brake Master Cylinder/Service and
Repair/Removal and Replacement/Master Cylinder Reservoir Replacement). Replace the brake
master cylinder reservoir cap diaphragm.
* Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose
Replacement)
* Rear Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Rear Brake Hose
Replacement)
* Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Brake Caliper Replacement)
* Wheel Cylinder Replacement (See: Wheel Cylinder/Service and Repair) , if equipped
* Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock
Brakes/Service and Repair)
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but
WAS contaminated with water or dirt, rust,
corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The
diaphragm may have allowed the moisture or particles to enter the hydraulic system.
5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM
P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder
reservoir filled to the maximum-fill level with the correct
brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic
Brake System Bleeding (Pressure) (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Testing and Inspection
Brake Caliper: Testing and Inspection
Brake Caliper Inspection Warning: Refer to Brake Dust Warning (See: Service
Precautions/Technician Safety Information/Brake Dust Warning).
1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these
conditions are present, the brake caliper requires
replacement.
2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper
seating in the caliper body. If any of these
conditions are present, the brake caliper requires overhaul or replacement.
3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake
pads. If there is any evidence of brake fluid
leakage, the brake caliper requires overhaul or replacement.
4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores:
The movement of the caliper pistons into the caliper bores should be smooth and even. If the
caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement.
* For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in
front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against
the brake pad or block of wood, slowly bottom the piston in the bore.
* For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in
front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against
the brake pad or block of wood, slowly bottom the pistons evenly into the bores.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement
Brake Caliper: Service and Repair Brake Caliper Replacement
Brake Caliper Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety
Information/Brake Fluid Irritant Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair) 2. Remove the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair
).
Note: Do not reuse the brake hose fitting gaskets.
3. Remove the brake hose fitting bolt (1), the brake hose fitting gaskets (2), and the brake hose
fitting (3) from the brake caliper.
Cap the brake hose fitting to prevent brake fluid loss and contamination.
4. Discard the brake hose fitting gaskets.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement > Page 6473
5. Remove the brake caliper guide pin bolts (1).
6. Remove the brake caliper (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement > Page 6474
1. Install the brake caliper (1).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the brake caliper guide pin bolts (1) and tighten to 64Nm (47 lb ft).
Note: Install new brake hose fitting gaskets.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement > Page 6475
3. Assemble the brake hose fitting bolt (1) and new brake hose fitting gaskets (2) to the brake hose
fitting (3). 4. Install the brake hose assembly to the brake caliper and tighten the fitting bolt to 40
Nm (30 lb ft). 5. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding
(Manual) (See: Brake Bleeding/Service and Repair)Hydraulic
Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair).
6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement > Page 6476
Brake Caliper: Service and Repair Brake Caliper Bracket Replacement
Brake Caliper Bracket Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair
).
Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support
the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which
may cause damage to the brake hose and in turn may cause a brake fluid leak.
3. Without disconnecting the front brake hose, remove the brake caliper and support with heavy
mechanics wire or equivalent. Refer to Brake Caliper
Replacement (See: Brake Caliper Replacement).
4. Remove the 2 brake caliper bracket bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement > Page 6477
5. Remove the brake caliper bracket. 6. Inspect the disc brake hardware for damage and replace, if
necessary. Refer to Disc Brake Mounting and Hardware Inspection (See: Disc Brake
System/Testing and Inspection/Component Tests and General Diagnostics).
Installation Procedure
1. Install the brake caliper bracket.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Replacement > Page 6478
2. Install the 2 brake caliper bracket bolts and tighten to 180 Nm (133 lb ft). 3. Install the brake
caliper. Refer to Brake Caliper Replacement (See: Brake Caliper Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications
Brake Fluid: Specifications
HYDRAULIC BRAKE SYSTEM DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 12377967, in
Canada 89021320).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6486
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6487
Brake Fluid Level Sensor/Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6488
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6489
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Page 6490
Brake Fluid Level Sensor/Switch: Diagrams
Component Connector End Views
Brake Fluid Level Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Page 6491
Brake Fluid Level Sensor/Switch: Service and Repair
Brake Fluid Level Indicator Switch Replacement
Removal Procedure
1. Remove the electrical connector from the sensor. 2. Using a pair of needle nose pliers bend on a
90 degree angle, release the retaining clip. 3. Remove the sensor from the master cylinder.
Installation Procedure
1. Install the fluid sensor in the master cylinder. Make sure that the sensor is fully seated. 2. Install
the electrical connector
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement
Brake Hose/Line: Service and Repair Brake Pipe Replacement
Brake Pipe Replacement
Special Tools
J 45405 Pipe Flaring Tool Kit
Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety
Information/Brake Fluid Irritant Warning).
Warning
Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe
is not recommended and may cause brake system failure. Carefully route and retain replacement
brake pipes. Always use the correct fasteners and the original location for replacement brake
pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and
cause brake system failure.
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
Note: When servicing the brake pipes, note the following:
* If sectioning the brake pipe, use replacement pipe of the same type and outside diameter.
* Use fittings of the appropriate size and type.
* Only create flares of the same type or design as originally equipped on the vehicle.
1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be
replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe,
if necessary.
* Allow adequate clearance in order to maneuver the J 45405 .
* Avoid sectioning the brake pipe at bends or mounting points.
4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5.
Add to the measurement taken the appropriate additional length required for each flare to be
created.
* 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe
* 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe
* 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6496
Note: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe
length.
6. Using the pipe cutter included in the J 45405 , carefully cut the brake pipe squarely to the
measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate
size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake
pipe size.
9. Strip the nylon coating from the brake pipe end to be flared, if necessary.
* Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading
the blade block from the stripping tool and installing the block with the desired blade facing the tool
rollers.
- 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe
- 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe
* Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool
rollers.
* While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel
of the tool until the blade contacts the brake pipe coated surface. Note: Do not gouge the metal
surface of the brake pipe.
* Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains
against the tool roller ledges.
* After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool
clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface
is exposed.
* Loosen the thumbwheel of the tool and remove the brake pipe. Note: Ensure that all loose
remnants of the nylon coating have been removed from the brake pipe.
* Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been
removed.
- 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe
- 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6497
10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J
45405 . 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe
and the J 45405 of lubricant, contaminants, and debris.
13. Loosen the die clamping screw of the J 45405 . 14. Select the corresponding die set and install
the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the
counterbores of both dies facing the forming ram.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6498
15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold
firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared
through the back of the dies until the pipe is seated against the flat surface of the unused die (1).
17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the
enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies.
20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic
fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it
bottoms against the die cage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6499
23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever
of the J 45405 until the forming mandrel bottoms
against the clamping dies.
24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the
hydraulic forming ram to retract.
25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve
clockwise to the closed position. 27. Rotate the body of the J 45405 until it bottoms against the die
cage. 28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the
lever of the J 45405 until the finishing cone bottoms
against the dies.
29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the
hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe.
31. If necessary, lightly tap the dies until the die halves separate.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6500
32. Inspect the brake pipe flare for correct shape and diameter (a).
* 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe
* 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe
* 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe
33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a
suitable brake pipe bending tool.
Important: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or
vibrating components.
34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If
previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system.
Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and
Repair)Hydraulic
Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair).
37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and
applying the brakes.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6501
Brake Hose/Line: Service and Repair Front Brake Hose Replacement
Front Brake Hose Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety
Information/Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Remove the front tire and wheel assembly. Refer to Tire and Wheel
Removal and Installation (See: Maintenance/Wheels and Tires/Service and
Repair).
3. Clean all dirt and foreign material from the brake hoses and the brake pipes. 4. Using a backup
wrench on the brake pipe fitting, disconnect the brake pipe from the brake hose.
Note: Install a plug or cap in the brake pipe fitting in order to prevent fluid loss and contamination.
5. Disconnect the brake pipe fitting from the brake hose at the frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6502
Note: Inspect the condition of the retaining clip. If the retaining clip is flattened or damaged, discard
and replace with new.
6. Remove the front brake hose retaining clip at the frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6503
7. Remove the bolt and gaskets from the brake caliper. 8. Remove the brake hose from the brake
caliper. 9. Remove the copper gaskets from the brake hose bolt. These gaskets may stick to the
brake caliper or the brake hose bolt.
Installation Procedure
Note: DO NOT reuse the old copper gaskets. Always use NEW metal copper gaskets.
1. Install the copper gaskets on the brake hose.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the brake caliper bolt to the brake caliper and tighten the bolt to 40 Nm (32 lb ft). 3.
Remove the plug or cap from the exposed brake pipe fitting. 4. Install the brake hose to the brake
pipe.
Note: Ensure that the brake hose is not twisted and does not come in contact with any of the
suspension components.
5. Using a backup wrench on the brake pipe fitting, tighten the brake hose fitting to 17 Nm (13 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6504
Note: Ensure that the retaining clip is properly seated.
6. Install the new brake pipe retaining clip. 7. Bleed the hydraulic brake system. Refer to Hydraulic
Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic
Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair).
8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair). 9. Lower the vehicle. Refer to Lifting and
Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6505
Brake Hose/Line: Service and Repair Rear Brake Hose Replacement
Rear Brake Hose Replacement
Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service
Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair).
Note: Inspect the condition of the retaining clip. If the retaining clip is flatten or damaged, discard
and replace with new.
2. Remove the retaining clip from the mounting bracket.
3. Using a backup wrench, remove the brake line from the brake hose.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6506
Note: Install a rubber cap or plug to the exposed brake pipe fitting in order to prevent brake fluid
loss and contamination.
4. Install a rubber cap or plug in the brake line.
5. Remove the brake line to the left wheel cylinder.
6. Remove the brake line to the right wheel cylinder. 7. Install a rubber cap or plug in the brake
lines.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6507
8. Remove the mounting bolt for the brake hose. 9. Remove the rear brake hose.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: When installing the mounting bolt to the brake hose or brake lines, always finger-tighten the
bolt before tightening to specification.
1. Install the brake line to the brake hose and tighten the mounting bolt to 17 Nm (13 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6508
2. Install the new retaining clip for the rear brake hose.
3. Position the rear brake hose on the mounting bracket.
Note: When installing the mounting bolt to the brake hose or brake lines, always finger-tighten the
bolt before tightening to specification.
4. Install the mounting bolt. 5. Remove the rubber plug or cap from the left brake line to the brake
hose.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6509
Note: When installing the brake hose or brake line fittings, always finger-tighten the fitting before
tightening to specification.
6. Install the left brake line to the brake hose and tighten the fitting to 19 Nm (14 lb ft). 7. Remove
the rubber cap or plug from the right brake line.
Note: When installing the brake hose or brake line fittings, always finger-tighten the fitting before
tightening to specification.
8. Install the right brake line to the brake hose and tighten the fitting to 19 Nm (14 lb ft). 9. Fill the
master cylinder reservoir, if needed. Refer to Master Cylinder Reservoir Filling (See: Brake Master
Cylinder/Service and
Repair/Procedures/Master Cylinder Reservoir Filling).
10. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake
Bleeding/Service and Repair)Hydraulic Brake System
Bleeding (Pressure) (See: Brake Bleeding/Service and Repair).
11. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6510
Brake Hose/Line: Service and Repair Power Brake Booster Vacuum Check Valve and Hose
Replacement
Power Brake Booster Vacuum Check Valve and Hose Replacement (5.3L)
Removal Procedure
1. Apply and release the brake pedal several times to deplete the vacuum brake booster vacuum
reserve. 2. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight
Shield Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair).
3. Disconnect the vacuum brake booster check valve (1) from the power vacuum brake booster.
Release the vacuum hose clamp and remove the check valve from the hose, if necessary.
4. Release the clamp and disconnect the vacuum hose (1) from the intake manifold vacuum port.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 6511
Installation Procedure
1. Connect the vacuum hose (1) from the intake manifold vacuum port.
Position the clamp to secure the hose to the intake manifold.
2. Install the check valve to the vacuum hose, if removed.
Position the clamp to secure the hose to the check valve.
3. Connect the vacuum brake booster check valve (1) to the power vacuum brake booster.
A small amount of denatured alcohol may be used as a lubricant to ease assembly, if necessary.
4. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake
Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake
Proportioning/Combination Valve: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel
Brake Proportioning/Combination Valve: Customer Interest Brakes - Brake Pedal
Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake
Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake
Proportioning/Combination Valve: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel >
Page 6520
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake
Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake
Proportioning/Combination Valve: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel >
Page 6521
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake
Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Brake Proportioning/Combination Valve: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal
Travel
Brake Proportioning/Combination Valve: All Technical Service Bulletins Brakes - Brake Pedal
Spongy/Increased Pedal Travel
TECHNICAL
Bulletin No.: 09-05-25-003
Date: September 21, 2009
Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks,
Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)
Models:
2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR
2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY
2009 Saturn VUE Equipped With RPO JL4 Only
Condition
Some customers may comment that over time the brake pedal has begun to feel spongy, that they
are experiencing increased pedal travel and an increased effort to stop.
Cause
This condition may be caused by air accumulating in the master cylinder or by a missing filter in the
brake pressure modulator valve (BPMV).
Correction
1. Perform the Diagnostic System Check - Vehicle.
‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not
present, proceed with this bulletin.
2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system
for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer
concern by road testing the vehicle.
Note Depending on the placement/orientation of the bar code label on the BPMV, it may be
necessary to use a mirror to view and identify the 4-digit numbers.
5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve
and compare it to the following list to verify if it is
one of the affected units.
List of Affected Units
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake
Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Brake Proportioning/Combination Valve: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal
Travel > Page 6527
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498
‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to
Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed
numbers, then refer to Brakes > Antilock Brake Systems and
Hydraulic Brakes in SI.
6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7.
Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid
container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9.
Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may
have been trapped in the BPMV. Refer to Antilock
Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the
vehicle to the customer.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake
Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Brake Proportioning/Combination Valve: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal
Travel > Page 6528
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Brake Pressure Modulator Valve Replacement
Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service
Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
1. Turn the ignition switch to the OFF position. 2. Disconnect the electronic brake control module
(EBCM) electrical connector.
3. Clean the area around the brake pipe fittings and the EBCM and the brake pressure modulator
valve (BPMV) mating surfaces of any accumulated
dirt and debris.
4. Disconnect the RF brake pipe fitting (1) from the EBCM/BPMV assembly.
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and
contamination.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6532
5. Disconnect the RR brake pipe fitting (1) from the EBCM/BPMV assembly.
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and
contamination.
6. Disconnect the LR brake pipe fitting (1) from the EBCM/BPMV assembly.
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and
contamination.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6533
7. Disconnect the LF brake pipe fitting (1) from the EBCM/BPMV assembly.
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and
contamination.
8. Disconnect the master cylinder primary brake pipe fitting (1) from the EBCM/BPMV assembly.
Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and
contamination.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6534
9. Disconnect the master cylinder secondary brake pipe fitting (1) from the EBCM/BPMV assembly.
Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and
contamination.
10. Remove the EBCM/BPMV assembly bracket nuts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6535
11. Remove the EBCM/BPMV assembly (1).
12. If necessary, remove the BPMV bracket bolts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6536
13. If necessary, remove the bracket (1) from the BPMV. 14. Remove the EBCM. Refer to
Electronic Brake Control Module Replacement (See: Antilock Brakes / Traction Control
Systems/Electronic Brake
Control Module/Service and Repair).
Installation Procedure
1. Install the EBCM. Refer to Electronic Brake Control Module Replacement (See: Antilock Brakes /
Traction Control Systems/Electronic Brake
Control Module/Service and Repair).
2. If removed, install the bracket (1) to the BPMV.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6537
3. If removed, install the BPMV bracket bolts (1) and tighten to 11 Nm (97 lb in).
4. Install the EBCM/BPMV assembly (1) to the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6538
5. Install the EBCM/BPMV assembly bracket nuts (1) and tighten to 9 Nm (80 lb in).
Connect the master cylinder secondary brake pipe fitting (1) to the EBCM/BPMV assembly and
tighten to 32 Nm (24 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6539
Connect the master cylinder primary brake pipe fitting (1) to the EBCM/BPMV assembly and
tighten to 32 Nm (24 lb ft).
Connect the LF brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6540
Connect the LR brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb ft).
6. Connect the RR brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb
ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6541
7. Connect the RF brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb
ft). 8. Connect the EBCM electrical connector. 9. Perform the Antilock Brake System Automated
Bleed Procedure (See: Brake Bleeding/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures
Brake Master Cylinder: Procedures
Master Cylinder Bench Bleeding
Master Cylinder Bench Bleeding Warning: Refer to Brake Fluid Irritant Warning (See: Service
Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the
primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install
suitable fittings to the master cylinder ports that match the type of flare seat required and also
provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master
cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder
reservoir to at least the half-way point with GM approved brake fluid from a clean, sealed brake
fluid container. Refer to
Master Cylinder Reservoir Filling (See: Master Cylinder Reservoir Filling).
6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully
submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the
primary piston as far as it will travel, a depth of about 25 mm (1 in), several times.
Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary
pistons, the effort required to depress the primary piston will increase and the amount of travel will
decrease.
8. Continue to depress and release the primary piston until fluid flows freely from the ports with no
evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir.
10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the
transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth
to prevent brake
fluid spills.
12. Remove the master cylinder from the vise.
Master Cylinder Reservoir Filling
Master Cylinder Reservoir Filling Warning: Refer to Brake Fluid Irritant Warning (See: Service
Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake
fluid level is at or below the half-full point during routine fluid checks, the brake system should be
inspected for wear and possible
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 6546
brake fluid leaks.
3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an
inspection of the brake system did not reveal wear or
brake fluid leaks, the brake fluid may be topped-off up to maximum-fill level.
4. If brake system service was just completed, the brake fluid may be topped-off up to the
maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not
recommended under normal conditions.
6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on
and around the reservoir cap prior to removing
the cap and diaphragm. Use only GM approved brake fluid from a clean, sealed brake fluid
container. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 6547
Brake Master Cylinder: Removal and Replacement
Master Cylinder Reservoir Replacement
Master Cylinder Reservoir Replacement
Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service
Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
1. Using a suitable tool, remove and properly discard the brake fluid from the master cylinder
reservoir. 2. Clean the master cylinder reservoir and master cylinder assembly with denatured
alcohol to remove any accumulated dirt and debris and allow to
dry.
3. Disconnect the brake fluid level indicator switch electrical connector.
4. Carefully spread the 4 master cylinder reservoir locking legs and lift the master cylinder reservoir
(1) upward.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 6548
5. Remove the master cylinder reservoir seals (1).
Installation Procedure
1. Lightly lubricate the master cylinder reservoir seals with the recommended brake fluid. Refer to
Fluid and Lubricant Recommendations (See:
Maintenance/Service Intervals).
2. Install the master cylinder reservoir seals (1).
3. Install the master cylinder reservoir (1) to the master cylinder.
Ensure the 4 locking legs of the master cylinder reservoir fully engage the master cylinder.
4. Connect the brake fluid level indicator switch electrical connector. 5. Fill the master cylinder
reservoir with the recommended brake fluid. Refer to Master Cylinder Reservoir Filling (See:
Procedures/Master
Cylinder Reservoir Filling).
Master Cylinder Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 6549
Master Cylinder Replacement
Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service
Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
1. Apply and release the brake pedal several times until the pedal becomes firm to deplete the
power vacuum brake booster vacuum reserve. 2. Using a suitable tool, remove and properly
discard the brake fluid from the master cylinder reservoir. 3. Clean the master cylinder assembly
with denatured alcohol to remove any accumulated dirt and debris and allow to dry. 4. Disconnect
the brake fluid level indicator switch electrical connector.
5. Disconnect the master cylinder secondary brake pipe fitting (1).
Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and
contamination.
6. Disconnect the master cylinder primary brake pipe fitting (1).
Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and
contamination.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 6550
7. Remove the master cylinder nuts (1).
8. Remove the master cylinder (1) and O-ring seal (2) from the power vacuum brake booster.
Inspect the O-ring seal for damage and replace, if necessary.
Installation Procedure
1. If installing a new master cylinder, bench bleed the master cylinder. Refer to Master Cylinder
Bench Bleeding (See: Procedures/Master Cylinder
Bench Bleeding).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 6551
2. Install the master cylinder (1) and O-ring seal (2) to the power vacuum brake booster.
Ensure the O-ring seal is properly positioned in the groove in the master cylinder body.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the master cylinder nuts (1) and tighten to 30 Nm (22 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 6552
4. Connect the master cylinder primary brake pipe fitting (1) and tighten to 17 Nm (13 lb ft).
5. Connect the master cylinder secondary brake pipe fitting (1) and tighten to 17 Nm (13 lb ft). 6.
Connect the brake fluid level indicator switch electrical connector. 7. Fill the master cylinder
reservoir with the recommended brake fluid. Refer to Master Cylinder Reservoir Filling (See:
Procedures/Master
Cylinder Reservoir Filling).
8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See:
Brake Bleeding/Service and Repair)Hydraulic
Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair
Wheel Cylinder: Service and Repair
Wheel Cylinder Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
1. Remove the rear brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake
System/Brake Shoe/Service and Repair).
2. Disconnect the brake pipe fitting (1) from the wheel cylinder.
Cap the brake pipe fitting and plug the wheel cylinder inlet port to prevent brake fluid loss and
contamination.
3. Remove the wheel cylinder bolts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Page 6556
4. Remove the wheel cylinder (1).
Installation Procedure
1. Install the wheel cylinder (1).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Page 6557
2. Install the wheel cylinder bolts (1) and tighten to 18 Nm (13 lb ft).
3. Connect the brake pipe fitting (1) to the wheel cylinder and tighten to 19 Nm (14 lb ft). 4. Install
the rear brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake
Shoe/Service and Repair). 5. Bleed the wheel cylinder. Refer to Hydraulic Brake System Bleeding
(Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake
System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures
Parking Brake Cable: Procedures
Parking Brake Cable Equalizer Replacement
Replacement Procedure
1. Release the park brake. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the park brake adjusting nut.
4. Remove the front park brake cable from the equalizer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6563
5. Remove the right rear park brake cable from the equalizer.
6. Remove the left rear park brake cable from the equalizer. 7. Remove the equalizer.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6564
1. Install the left rear park brake cable in the equalizer.
2. Install the right rear park brake cable in the equalizer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6565
3. Install the front park brake cable in the equalizer.
4. Install the park brake cable adjusting nut. 5. Adjust the park brake cable. Refer to Parking Brake
Adjustment (See: Adjustments). 6. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6566
Parking Brake Cable: Removal and Replacement
Parking Brake Release Cable Replacement
Parking Brake Release Cable Replacement
Removal Procedure
1. Release the park brake pedal. 2. Remove the knee bolster panel. Refer to Knee Bolster
Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair).
3. Press the locking tabs for the release handle.
4. Remove the release handle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6567
5. Press the locking tabs for the release cable at the lower dash panel. 6. Remove the release
cable from the lower dash panel.
7. Remove the release cable from the park brake pedal mounting bracket. 8. Remove the release
cable from the release lever. 9. Remove the release cable.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6568
Important: Ensure that the release cable is properly seated in the release lever.
1. Install the release cable to the release lever.
Important: When installing the park brake release handle or cable, ensure that the locking tabs are
properly seated. A snap or clip should be heard or felt if installed properly.
2. Attach the release cable in the park brake pedal mounting bracket.
3. Install the release cable to the knee bolster panel. 4. Install the knee bolster panel. Refer to
Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6569
5. Install the park brake release handle to the release cable.
Parking Brake Rear Cable Replacement - Left Side
Parking Brake Rear Cable Replacement - Left Side
Special Tools
J 37043 Parking Brake Cable Release Tool
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety
Information/Brake Fluid Irritant Warning).
1. Release the park brake.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6570
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the park brake cable adjusting nut.
4. Remove the front park brake cable from the equalizer.
5. Remove the left rear park brake cable from the equalizer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6571
6. On long wheel base vehicles, remove the park brake cable at the left frame rail.
7. Remove the retaining bolt from the left rear park brake cable. 8. On short wheel base vehicles,
remove the park brake cable from the left frame rail.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6572
9. Remove the retainer for the park brake cables at the left frame rail.
10. Remove the park brake cable retaining nut at the left rear leaf spring. 11. Remove the left rear
park brake cable retaining bracket. 12. Remove the rear brake shoes. Refer to Brake Shoe
Replacement (See: Drum Brake System/Brake Shoe/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6573
13. Using the J 37043 (1), remove the park brake cable from the backing plate.
14. Remove the park brake cable from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6574
1. Install the park brake cable into the backing plate. 2. Install the rear brake shoes. Refer to Brake
Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair).
3. Install the park brake cable to the retaining bracket at the rear leaf spring.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the retaining nut and tighten to 9 Nm (80 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6575
5. Install the park brake cable to the left rear frame rail. 6. Install the retaining bolts and tighten to 9
Nm (80 lb in).
7. On short wheel base vehicles, install the park brake cable in the retaining bracket. 8. Install the
retaining bolt for the park brake cable and tighten to 9 Nm (80 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6576
9. On long wheel base vehicles, install the park brake cable in the retaining bracket.
10. Install the left rear park brake cable to the park brake equalizer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6577
11. Install the front park brake cable in the equalizer.
12. Install the adjuster nut. 13. Adjust the park brake. Refer to Parking Brake Adjustment (See:
Adjustments). 14. Lower the vehicle.
Parking Brake Rear Cable Replacement - Right Side
Parking Brake Rear Cable Replacement - Right Side
Special Tools
J 37043 Parking Brake Cable Release Tool
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6578
Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety
Information/Brake Fluid Irritant Warning).
1. Release the park brake, if applied. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle
(See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the adjusting nut for the park
brake.
4. Remove the front park brake cable from the equalizer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6579
5. Remove the right park brake cable from the equalizer.
6. On short wheel base vehicles, remove the right park brake cable from the retainer on the left
frame rail. 7. Remove the retaining bolt for the right park brake cable.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6580
8. On long wheel base vehicles, remove the right park brake cable from the retainer on the left
frame rail. 9. Remove the retaining bolt for the park brake cable.
10. Remove the park brake cable from the crossmember.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6581
11. Remove the right park brake cable retaining bolts from the right rear frame rail.
12. Remove the retaining nut at the right rear spring bracket. 13. Remove the park brake cable
from the retaining bracket. 14. Remove the rear brakes shoes. Refer to Brake Shoe Replacement
(See: Drum Brake System/Brake Shoe/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6582
15. Using the J 37043 (1), remove the park brake cable from the backing plate.
16. Remove the park brake cable from the backing plate.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6583
1. Install the park cable in the backing plate. 2. Install the rear brake shoes. Refer to Brake Shoe
Replacement (See: Drum Brake System/Brake Shoe/Service and Repair).
3. Install the park brake cable to the rear spring retaining bracket.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the retaining nut to the park brake cable and tighten to 9 Nm (80 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6584
5. Install the park brake cable retaining bolts to the right rear frame rail and tighten to 9 Nm (80 lb
in).
6. Install the park brake cable to the crossmember.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6585
7. On long wheel base vehicles, install the park brake cable to the left frame rail and tighten to 9
Nm (80 lb in). 8. Install the park brake cable retaining bolts and tighten to 9 Nm (80 lb in).
9. On short wheel base vehicles, install the park brake cable to the left frame rail.
10. Install the park brake cable retaining bolt and tighten to 9 Nm (80 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6586
11. Install the park brake cable to the equalizer.
12. Install the front park brake cable to the equalizer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6587
13. Loosely install the adjuster nut. 14. Adjust the park brakes. Refer to Parking Brake Adjustment
(See: Adjustments). 15. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Service and Repair
Parking Brake Lever: Service and Repair
Parking Brake Lever Pedal Assembly Replacement
Removal Procedure
1. Release the park brake. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the wheel house inner liner. Refer to
Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
4. Remove the park brake cable adjusting nut.
5. Remove the front park brake cable from the equalizer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Service and Repair > Page 6591
6. Remove the retaining bolt for the front park brake cable. 7. Remove the knee bolster panel.
Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument
Panel/Service and Repair).
8. Remove the clutch pedal assembly. Refer to Clutch Pedal Replacement (See: Transmission and
Drivetrain/Clutch/Clutch Pedal Assembly/Service
and Repair).
9. Remove the electrical connector from the brake switch.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Service and Repair > Page 6592
10. Remove the park brake cable pedal mounting bolts. 11. Remove the front park brake cable
weather seal. 12. Remove the park brake pedal assembly from the vehicle. 13. Remove the front
park brake pedal and cable assembly from the vehicle noting routing for installation.
Installation Procedure
1. Install the park brake pedal and cable assembly as previously routed.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the mounting bolts for the park brake pedal assembly and tighten to 20 Nm (15 lb ft). 3.
Install the front park brake cable weather seal. 4. Install the clutch pedal assembly. Refer to Clutch
Pedal Replacement (See: Transmission and Drivetrain/Clutch/Clutch Pedal Assembly/Service
and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Service and Repair > Page 6593
5. Install the retaining bolt for the front park brake cable at the wheel well and tighten the bolt to 20
Nm (15 lb ft).
6. Install the front park brake cable to the equalizer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Service and Repair > Page 6594
7. Install the park brake cable adjusting nut. Refer to Parking Brake Adjustment (See:
Adjustments). 8. Install the wheel house liner. Refer to Front Wheelhouse Liner Replacement (See:
Body and Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair).
9. Install the knee bolster panel. Refer to Knee Bolster Replacement (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair).
10. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch >
Component Information > Locations > Harness Routing Views
Parking Brake Release Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch >
Component Information > Locations > Harness Routing Views > Page 6599
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch >
Component Information > Locations > Harness Routing Views > Page 6600
6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger
Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center
High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat
Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2
15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch
Switch 24 - Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to
Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200
(I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch
Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door
Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch >
Component Information > Locations > Harness Routing Views > Page 6601
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch >
Component Information > Locations > Harness Routing Views > Page 6602
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch >
Component Information > Locations > Harness Routing Views > Page 6603
Parking Brake Release Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Below the I/P Components - 2 of 2
1 - Park Brake Switch Connector 2 - Body Harness 3 - Park Brake Switch 4 - Park Brake Lever 5 Cowl Side Inner Panel
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch >
Component Information > Locations > Page 6604
Parking Brake Release Switch: Diagrams
Component Connector End Views
Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Remove the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair).
2. Remove the electrical connector.
3. Remove the park brake warning lamp switch mounting bolt.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Service and Repair > Page 6608
4. Remove the park brake warning lamp switch from the vehicle.
Installation Procedure
1. Install the park brake warning lamp switch.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the park brake warning lamp switch mounting bolt and tighten to 4 Nm (35 lb in).
3. Install the electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Service and Repair > Page 6609
4. Install the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair
Vacuum Brake Booster: Service and Repair
Power Vacuum Brake Booster Replacement
Removal Procedure
1. Apply and release the brake pedal several times until the pedal becomes firm to deplete the
brake booster vacuum reserve.
2. Disconnect the power vacuum brake booster vacuum hose and check valve (1). 3. Remove the
master cylinder assembly. Refer to Master Cylinder Replacement (See: Hydraulic System/Brake
Master Cylinder/Service and
Repair/Removal and Replacement/Master Cylinder Replacement).
4. Remove the knee bolster. Refer to Knee Bolster Replacement (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair).
5. Remove the brake booster pushrod retainer (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Page 6614
6. Remove the brake booster pushrod clevis pin (1).
7. Remove the power vacuum brake booster nuts (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Page 6615
8. Remove the power vacuum brake booster (1). 9. Remove the power vacuum brake booster
gasket (2).
Inspect the gasket for damage and replace, if necessary.
Installation Procedure
1. Install the power vacuum brake booster (1) and gasket (2).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Page 6616
2. Install the power vacuum brake booster nuts (1) and tighten to 20 Nm (15 lb ft).
3. Install the brake booster pushrod clevis pin (1) to the pushrod and the brake pedal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Page 6617
4. Install the brake booster pushrod retainer (1). 5. Install the knee bolster. Refer to Knee Bolster
Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair).
6. Install the master cylinder assembly. Refer to Master Cylinder Replacement (See: Hydraulic
System/Brake Master Cylinder/Service and
Repair/Removal and Replacement/Master Cylinder Replacement).
7. Connect the power vacuum brake booster vacuum hose and check valve (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component
Views
Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component
Views > Page 6623
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component
Views > Page 6624
Electronic Brake Control Module: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component
Views > Page 6625
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component
Views > Page 6626
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Page 6627
Electronic Brake Control Module: Diagrams
Component Connector End Views
Electronic Brake Control Module (EBCM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Page 6628
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Page 6629
Electronic Brake Control Module: Service and Repair
Electronic Brake Control Module Replacement
Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service
Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Caution).
1. Turn the ignition switch to the OFF position. 2. Remove the brake pressure modulator valve
(BPMV). Refer to Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction
Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair).
3. Remove the electronic brake control module (EBCM) bolts (1).
Discard the bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Page 6630
4. Carefully separate the EBCM (1) from the BPMV. 5. Remove the 12 EBCM to BPMV seals (2).
Installation Procedure
1. Carefully install the EBCM (1) and the 12 seals (2) to the BPMV.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: Do not reuse the EBCM bolts. Install new bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Page 6631
2. Install new EBCM bolts (1) and tighten to 2 Nm (18 lb in). 3. Install the EBCM/BPMV assembly to
the vehicle. Refer to Brake Pressure Modulator Valve Replacement (See: Antilock Brakes /
Traction
Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair
Acceleration/Deceleration Sensor: Service and Repair
Longitudinal Accelerometer Replacement
Removal Procedure
1. Remove the left front seat. Refer to Front Seat Replacement - Bucket (See: Body and
Frame/Seats/Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split
Bench Seat Replacement).
2. Access the sensor through service slit provided in the carpet. 3. Disconnect the longitudinal
accelerometer electrical connector.
4. Remove the nuts (1) from the longitudinal accelerometer. 5. Remove the longitudinal
accelerometer.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 6636
1. Install the longitudinal accelerometer.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the longitudinal accelerometer nuts (1) and tighten to 9 Nm (80 lb in). 3. Connect the
longitudinal accelerometer electrical connector. 4. Install the left front seat. Refer to Front Seat
Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split
Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
> Page 6641
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
> Page 6642
Brake Fluid Level Sensor/Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
> Page 6643
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
> Page 6644
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 6645
Brake Fluid Level Sensor/Switch: Diagrams
Component Connector End Views
Brake Fluid Level Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 6646
Brake Fluid Level Sensor/Switch: Service and Repair
Brake Fluid Level Indicator Switch Replacement
Removal Procedure
1. Remove the electrical connector from the sensor. 2. Using a pair of needle nose pliers bend on a
90 degree angle, release the retaining clip. 3. Remove the sensor from the master cylinder.
Installation Procedure
1. Install the fluid sensor in the master cylinder. Make sure that the sensor is fully seated. 2. Install
the electrical connector
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Lateral Accelerometer > Component Information > Locations
Lateral Accelerometer: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Lateral Accelerometer > Component Information > Locations > Page 6650
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Lateral Accelerometer > Component Information > Locations > Page 6651
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Lateral Accelerometer > Component Information > Locations > Page 6652
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Lateral Accelerometer > Component Information > Locations > Page 6653
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Lateral Accelerometer > Component Information > Locations > Page 6654
Lateral Accelerometer: Diagrams
Component Connector End Views
Yaw and Lateral Accelerometer Sensor (2WD) (JL4)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Release Switch > Component Information > Locations > Harness Routing Views
Parking Brake Release Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6659
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6660
6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger
Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center
High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat
Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2
15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch
Switch 24 - Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to
Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200
(I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch
Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door
Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6661
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6662
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6663
Parking Brake Release Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Below the I/P Components - 2 of 2
1 - Park Brake Switch Connector 2 - Body Harness 3 - Park Brake Switch 4 - Park Brake Lever 5 Cowl Side Inner Panel
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Release Switch > Component Information > Locations > Page 6664
Parking Brake Release Switch: Diagrams
Component Connector End Views
Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Warning Switch > Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Remove the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair).
2. Remove the electrical connector.
3. Remove the park brake warning lamp switch mounting bolt.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Warning Switch > Component Information > Service and Repair > Page 6668
4. Remove the park brake warning lamp switch from the vehicle.
Installation Procedure
1. Install the park brake warning lamp switch.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the park brake warning lamp switch mounting bolt and tighten to 4 Nm (35 lb in).
3. Install the electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Warning Switch > Component Information > Service and Repair > Page 6669
4. Install the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Traction Control Switch > Component Information > Diagrams
Traction Control Switch: Diagrams
Component Connector End Views
Traction Control Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Traction Control Switch > Component Information > Diagrams > Page 6673
Traction Control Switch: Service and Repair
Electronic Traction Control Switch Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
Wheel Speed Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 6678
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 6679
Wheel Speed Sensor: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 6680
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 6681
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 6682
Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views
Wheels/Vehicle Underbody Component Views
Front Wheel Knuckle Components
1 - Wheel Speed Sensor (WSS) - Right Front 2 - Wheel Speed Sensor (WSS) - Left Front
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Locations > Page 6683
Wheel Speed Sensor: Diagrams
Component Connector End Views
Wheel Speed Sensor (WSS) - Left Front
Wheel Speed Sensor (WSS) - Right Front
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Locations > Page 6684
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement
Front Wheel Speed Sensor Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
1. Within the engine compartment, disconnect the wheel speed sensor electrical connector (1). 2.
Release the wheel speed sensor harness connector from the wheelhouse. 3. Raise and support
the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and
Repair). 4. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation
(See: Maintenance/Wheels and Tires/Service and Repair
).
5. Release the wheel speed sensor harness clips (1) from the suspension upper control arm.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page
6687
6. Release the wheel speed sensor harness grommet (1) from the mounting bracket.
7. Remove the wheel speed sensor harness bracket bolt (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page
6688
8. Thoroughly clean the wheel speed sensor mounting area of the steering knuckle of any dirt and
debris. 9. Remove the wheel speed sensor bolt (1).
Note: Do not pry or lever against the wheel speed sensor to remove.
10. Carefully remove the wheel speed sensor from the suspension knuckle by pulling straight
upward.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page
6689
1. Install the wheel speed sensor to the suspension knuckle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the wheel speed sensor bolt (1) and tighten to 8 Nm (71 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page
6690
3. Install the wheel speed sensor harness bracket bolt (1) and tighten to 9 Nm (80 lb in).
4. Install the wheel speed sensor harness grommet (1) to the mounting bracket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page
6691
5. Install the wheel speed sensor harness clips (1) to the suspension upper control arm.
6. Install the wheel speed sensor harness connector to the wheelhouse. 7. Connect the wheel
speed sensor electrical connector (1). 8. Install the tire and wheel assembly. Refer to Tire and
Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9.
Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnostic System
Check - Vehicle).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page
6692
Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement
Rear Wheel Speed Sensor Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician
Safety Information/Brake Dust Warning).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the wheel speed sensor bolts (1).
3. Remove the wheel speed sensor (1) from the drum brake backing plate by carefully pulling
straight outward.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page
6693
4. Release the wheel speed sensor harness retainers (1) on the rear park brake cable.
Release the harness from the retainers.
5. Disconnect the wheel speed sensor electrical connector (1). 6. Release the electrical connector
and harness retainer (2) from the frame. 7. Remove the wheel speed sensor assembly.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page
6694
1. Position the wheel speed sensor assembly to the vehicle. 2. Connect the wheel speed sensor
electrical connector (1). 3. Install the electrical connector and harness retainer (2) to the frame.
4. Position the wheel speed sensor harness to the retainers (1) on the rear park brake cable. 5.
Fasten the wheel speed sensor harness retainers.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page
6695
6. Install the wheel speed sensor (1) to the drum brake backing plate.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. Install the wheel speed sensor bolts (1) and tighten to 17 Nm (13 lb ft). 8. Lower the vehicle. 9.
Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnostic System
Check - Vehicle).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Locations
Yaw Rate Sensor: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Locations > Page 6699
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Locations > Page 6700
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Locations > Page 6701
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Locations > Page 6702
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Locations > Page 6703
Yaw Rate Sensor: Diagrams
Component Connector End Views
Yaw and Lateral Accelerometer Sensor (2WD) (JL4)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Locations > Page 6704
Yaw Rate Sensor: Service and Repair
Vehicle Yaw Sensor Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations
Clutch Switch: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations > Page 6710
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations > Page 6711
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations > Page 6712
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations > Page 6713
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
This vehicle has two different types of ignition lock cylinders based on what type of steering column
the vehicle is equipped with. The electric power steering (EPS) option, usually found on 4 cylinder
models, and the non EPS, usually found on 6 cylinder models, use different ignition lock cylinder
designs.
Ignition Lock Cylinder
The ignition lock cylinder uses all 10 key cut positions, 1-10 when counting from the key head. The
tumbler orientations alternate in adjacent locations from side to side with 5 tumblers on each side.
Important: The ignition lock cylinder tumblers (1) are not self retaining and must be held in place if
the key is not fully inserted in the lock cylinder (2), or until the lock cylinder (2) is assembled into
the case assembly (5).
1. Hold the uncoded cylinder assembly (2) positioned so the side with the security plug (3) faces to
the left of the key head. 2. Insert one tumbler spring (7) into each of the 4 tumbler spring holes. 3.
The first tumbler (1) to be loaded will be key cut position 1, the first number in the key code. Install
this tumbler in the tumbler slot closest to the
head of the lock cylinder (2), the end where the key is inserted.
4. Advancing one tumbler slot at a time, install tumblers 3, 5, and 7 sequentially on the same side
as tumbler 1. 5. Turn the lock cylinder over and insert one tumbler spring (7) into each of the 4
tumbler spring holes on the opposite side of the lock cylinder. 6. Insert tumbler 2 into the tumbler
slot closest to the head of the lock cylinder (2), the end where the key is inserted. 7. Advancing one
tumbler slot at a time, install tumblers 4, 6, and 8 sequentially on the same side as tumbler 2. 8.
Check for correct tumbler loading by holding the tumblers (1) in position and inserting the correct
key into the lock cylinder. All tumblers (1)
should be flush with the housing of the lock cylinder.
9. Lightly lubricate the tumblers and small detent recessed areas the tumblers are in with GM
Super Lube GM P/N 12346241 or equivalent light
lithium grease.
10. Take the slide piece and insert into the rotor. Ensure "Front of Sliding Piece" is facing the front
face of the rotor. If the slide piece is installed
incorrectly, the key cannot insert into the rotor due to no access to the ramp.
11. Install the pivot pin into the actuator lever and install the actuator lever into the ignition lock
cylinder housing. Ensure that the actuator lever is
inside of the lock cylinder housing at the end close to key insertion opening. Actuator lever should
pivot on the pin against spring tension.
12. Insert the key into the coded lock cylinder (2) and hold the lock cylinder positioned so the side
with the security plug (3) faces to the left of the key
head.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 6719
13. Hold the ignition lock housing positioned so the security plug actuator lever (3) also faces to the
right of the key head. 14. Push the exposed end of the security plug actuator lever (3) toward the
center of the lock cylinder housing (1) and hold it. Insert the coded lock
cylinder (2) with the key in it into the ignition lock cylinder housing (1) until the cap is flush with the
housing.
15. Rotate the keyed lock cylinder counterclockwise slightly until it stops and detents outward
slightly. The key should be able to be removed and the
lock cylinder should remain in the housing.
16. Install the retaining clip (1) onto the coded lock cylinder where it comes out of the back of the
lock cylinder housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 6720
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Removal Procedure
1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition
Lock Cylinder Replacement). 2. Remove the multifunction turn signal switch housing. Refer to
Multifunction Turn Signal Switch Housing Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch
Housing Replacement).
3. Remove the shear bolt from the ignition lock cylinder case using a hammer and chisel. 4.
Remove the ignition lock cylinder case.
Installation Procedure
1. Install the ignition lock cylinder case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the ignition lock cylinder case bolt and tighten it until the head shears off. 3. Install the
multifunction turn signal switch. Refer to Multifunction Turn Signal Switch Housing Replacement
(See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch
Housing Replacement).
4. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock
Cylinder Replacement). 5. The passlock sensor is part of the ignition switch. If replacing the ignition
switch, a passlock relearn will be needed. Refer to Control Module
References (See: Testing and Inspection/Programming and Relearning).
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Removal Procedure
1. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
2. Turn the ignition lock cylinder to the accessory position. 3. Insert the 90 degree tip of a pick type
tool into the ignition lock cylinder access hole. 4. Push and hold the ignition lock cylinder retaining
pin down.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 6721
5. Pull the ignition lock cylinder away from the steering column.
Installation Procedure
1. Install the ignition lock cylinder by performing the following procedure:
1. Turn the ignition lock cylinder to the accessory position. 2. Push the ignition lock cylinder in until
the retaining pin locks it in place.
2. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Battery Control
Module > Component Information > Diagrams
Battery Control Module: Diagrams
Component Connector End Views
Generator Battery Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Charging System
Control Module > Component Information > Service and Repair > Generator Battery Control Module Replacement
Charging System Control Module: Service and Repair Generator Battery Control Module
Replacement
Generator Battery Control Module Replacement (V8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Charging System
Control Module > Component Information > Service and Repair > Generator Battery Control Module Replacement > Page
6730
Charging System Control Module: Service and Repair Generator Battery Control Module
Replacement (4 and 5 Cylinder)
Generator Battery Control Module Replacement (4 and 5 Cylinder)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System
Information > Service and Repair
Negative: Service and Repair
Battery Negative Cable Replacement (LH8) (5.3L)
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Service and Repair). 2. Remove the negative battery cable clip (2) from the lower
half of the battery box. 3. Remove the negative battery cable clip (3) from the battery tray. 4.
Remove the negative battery cable integral bolt (4) from the battery tray.
5. Disconnect the engine wiring harness electrical connector (6) from the battery current sensor (5).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System
Information > Service and Repair > Page 6739
6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 7. Remove the negative battery cable ground bolt
(4). 8. Remove the negative battery cable clip (2) from the engine wiring harness bracket. 9. Lower
the vehicle.
10. Remove the negative battery cable clip (1) from the engine wiring harness bracket. 11. Remove
the negative battery cable (3) from the vehicle.
Installation Procedure
Note:
* The negative battery cable must not be connected to the battery prior to the installation of the
engine harness ground terminal to the engine block.
* The negative battery cable must not be connected to the battery prior to the installation of the
instrument panel harness and the engine harness to the powertrain control module.
1. Install the negative battery cable (3) to the vehicle. 2. Install the negative battery cable clip (1) to
the engine wiring harness bracket. 3. Raise and suitably support the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System
Information > Service and Repair > Page 6740
4. Install the negative battery cable clip (2) to the engine wiring harness bracket. 5. Ensure that the
engine wiring harness ground terminal (5) is position against the engine block.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Position the negative battery cable ground terminal over the engine wiring harness ground and
install the negative battery cable ground bolt (4).
Tighten the bolt to 25 Nm (18 lb ft).
7. Lower the vehicle.
8. Connect the engine wiring harness electrical connector (6) to the battery current sensor (5).
9. Install the negative battery cable integral bolt (4) to the battery tray.
Tighten the bolt to 40 Nm (29.5 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System
Information > Service and Repair > Page 6741
10. Install the negative battery cable clip (3) to the battery tray. 11. Install the negative battery cable
clip (2) to the lower half of the battery box. 12. Connect the negative battery cable. Refer to Battery
Negative Cable Disconnection and Connection (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Control Module > Component Information >
Diagrams
Battery Control Module: Diagrams
Component Connector End Views
Generator Battery Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and
Repair > Battery Tray Replacement
Battery Tray: Service and Repair Battery Tray Replacement
Battery Tray Replacement
Removal Procedure
Warning: Refer to Approved Equipment for Collision Repair Warning (See: Body and
Frame/Service Precautions/Approved Equipment for Collision Repair Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Battery Cable/Service and Repair).
3. Remove all related panels and components. 4. Repair as much of the damage as possible to
factory specifications. Refer to Dimensions - Body (). 5. Note the location and remove the sealers
and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment
and
Repair ().
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and
Repair > Battery Tray Replacement > Page 6749
Note: Do not damage any inner panels or reinforcements.
6. Locate and drill out all factory welds. Note the number and location of welds for installation of the
battery tray.
7. Remove the damaged battery tray.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and
Repair > Battery Tray Replacement > Page 6750
Note: If the location of the original plug weld holes can not be determined, or if structural weld-thru
adhesive is present, space the plug weld holes every 40 mm (11/2 in) apart.
1. Drill 8 mm (5/16 in) plug weld holes as necessary in locations noted from the original battery
tray. 2. Prepare all mating surfaces as necessary. 3. Apply GM-approved Weld-Thru coating or
equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair ().
4. Position the battery tray.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and
Repair > Battery Tray Replacement > Page 6751
5. Plug the weld accordingly.
6. Clean and prepare all welded surfaces. 7. Apply the sealers and anti-corrosion materials to the
repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (). 8. Paint the repair
area. Refer to Basecoat/Clearcoat Paint Systems (See: Body and Frame/Paint, Striping and
Decals/Paint/Application and
ID/Basecoat/Clearcoat Paint Systems).
9. Install all related panels and components.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Battery Cable/Service and Repair). 11. Enable the SIR system. Refer to SIR
Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and
Repair > Battery Tray Replacement > Page 6752
Battery Tray: Service and Repair Battery Box Replacement
Battery Box Replacement
Removal Procedure
1. Remove the battery. Refer to Battery Replacement (LLV/LLR) (See: Service and Repair)Battery
Replacement (LH8) (See: Service and Repair).
2. Disconnect the following from the lower battery box (2):
* The battery cables harness retainer (3)
* The engine wiring harness retainer
3. Lift the lower battery box (2) upward from the battery tray (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and
Repair > Battery Tray Replacement > Page 6753
Installation Procedure
1. Install the lower battery box (2) to the retainer stud (1) and battery tray (3).
2. Connect the following to the lower battery box (2):
* The battery cables harness retainer (3)
* The engine wiring harness retainer
3. Install the battery. Refer to Battery Replacement (LLV/LLR) (See: Service and Repair)Battery
Replacement (LH8) (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications
Alternator: Specifications
Generator Usage
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 6758
Alternator: Diagrams
Component Connector End Views
Generator X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service
and Repair > Generator Bracket Replacement
Alternator: Service and Repair Generator Bracket Replacement
Generator Bracket Replacement (LH8) (5.3L)
Removal Procedure
1. Remove the generator. Refer to Generator Replacement (LLV/LLR) (See: Generator
Replacement)Generator Replacement (LH8) (See:
Generator Replacement).
2. Remove the power steering pump. Refer to Power Steering Pump Replacement (LLV, LLR)
(See: Steering and Suspension/Steering/Power
Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (LH8)
(See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and
Repair).
3. Remove the drive belt idler pulley. Refer to Drive Belt Idler Pulley Replacement (See: Engine,
Cooling and Exhaust/Engine/Drive Belts, Mounts,
Brackets and Accessories/Idler Pulley/Service and Repair).
4. Remove the engine wiring harness bracket bolt (4). 5. Reposition the engine wiring harness
bracket out of the way.
6. Remove the generator bracket bolts. 7. Remove the generator bracket.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service
and Repair > Generator Bracket Replacement > Page 6761
1. Install the generator bracket.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the generator bracket bolts and tighten to 50 Nm (37 lb ft).
3. Position the engine wiring harness bracket to the generator bracket. 4. Install the engine wiring
harness bracket bolt (4) and tighten to 40 Nm (29.5 lb ft). 5. Install the drive belt idler pulley. Refer
to Drive Belt Idler Pulley Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts,
Brackets and Accessories/Idler Pulley/Service and Repair).
6. Install the power steering pump. Refer to Power Steering Pump Replacement (LLV, LLR) (See:
Steering and Suspension/Steering/Power
Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (LH8)
(See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and
Repair).
7. Install the generator. Refer to Generator Replacement (LLV/LLR) (See: Generator
Replacement)Generator Replacement (LH8) (See: Generator
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service
and Repair > Generator Bracket Replacement > Page 6762
Alternator: Service and Repair Generator Replacement
Generator Replacement (LH8) (5.3L)
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Battery/Battery Cable/Service and
Repair).
2. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement
(See: Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
3. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Engine,
Cooling and Exhaust/Engine/Drive Belts, Mounts,
Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory).
4. Disconnect the engine wiring harness electrical connector (1) from the generator. 5. Reposition
the engine wiring harness/positive battery cable boot (5). 6. Remove the engine wiring
harness/positive battery cable nut from the generator. 7. Remove the engine wiring
harness/positive battery cable (2) from the generator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service
and Repair > Generator Bracket Replacement > Page 6763
8. Remove the generator bolts. 9. Remove the generator.
Installation Procedure
1. Install the generator.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the generator bolts.
Tighten the bolts to 50 Nm (37 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service
and Repair > Generator Bracket Replacement > Page 6764
3. Install the engine wiring harness/positive battery cable (2) to the generator. 4. Install the engine
wiring harness/positive battery cable nut to the generator.
Tighten the nut to 9 Nm (80 lb in).
5. Position the engine wiring harness/positive battery cable boot (5). 6. Connect the engine wiring
harness electrical connector (1) to the generator. 7. Install the accessory drive belt. Refer to Drive
Belt Replacement - Accessory (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts,
Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory).
8. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair).
9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Battery/Battery Cable/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Charging System Control Module >
Component Information > Service and Repair > Generator Battery Control Module Replacement
Charging System Control Module: Service and Repair Generator Battery Control Module
Replacement
Generator Battery Control Module Replacement (V8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Charging System Control Module >
Component Information > Service and Repair > Generator Battery Control Module Replacement > Page 6769
Charging System Control Module: Service and Repair Generator Battery Control Module
Replacement (4 and 5 Cylinder)
Generator Battery Control Module Replacement (4 and 5 Cylinder)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information >
Locations
Clutch Switch: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information >
Locations > Page 6774
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information >
Locations > Page 6775
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information >
Locations > Page 6776
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information >
Locations > Page 6777
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
This vehicle has two different types of ignition lock cylinders based on what type of steering column
the vehicle is equipped with. The electric power steering (EPS) option, usually found on 4 cylinder
models, and the non EPS, usually found on 6 cylinder models, use different ignition lock cylinder
designs.
Ignition Lock Cylinder
The ignition lock cylinder uses all 10 key cut positions, 1-10 when counting from the key head. The
tumbler orientations alternate in adjacent locations from side to side with 5 tumblers on each side.
Important: The ignition lock cylinder tumblers (1) are not self retaining and must be held in place if
the key is not fully inserted in the lock cylinder (2), or until the lock cylinder (2) is assembled into
the case assembly (5).
1. Hold the uncoded cylinder assembly (2) positioned so the side with the security plug (3) faces to
the left of the key head. 2. Insert one tumbler spring (7) into each of the 4 tumbler spring holes. 3.
The first tumbler (1) to be loaded will be key cut position 1, the first number in the key code. Install
this tumbler in the tumbler slot closest to the
head of the lock cylinder (2), the end where the key is inserted.
4. Advancing one tumbler slot at a time, install tumblers 3, 5, and 7 sequentially on the same side
as tumbler 1. 5. Turn the lock cylinder over and insert one tumbler spring (7) into each of the 4
tumbler spring holes on the opposite side of the lock cylinder. 6. Insert tumbler 2 into the tumbler
slot closest to the head of the lock cylinder (2), the end where the key is inserted. 7. Advancing one
tumbler slot at a time, install tumblers 4, 6, and 8 sequentially on the same side as tumbler 2. 8.
Check for correct tumbler loading by holding the tumblers (1) in position and inserting the correct
key into the lock cylinder. All tumblers (1)
should be flush with the housing of the lock cylinder.
9. Lightly lubricate the tumblers and small detent recessed areas the tumblers are in with GM
Super Lube GM P/N 12346241 or equivalent light
lithium grease.
10. Take the slide piece and insert into the rotor. Ensure "Front of Sliding Piece" is facing the front
face of the rotor. If the slide piece is installed
incorrectly, the key cannot insert into the rotor due to no access to the ramp.
11. Install the pivot pin into the actuator lever and install the actuator lever into the ignition lock
cylinder housing. Ensure that the actuator lever is
inside of the lock cylinder housing at the end close to key insertion opening. Actuator lever should
pivot on the pin against spring tension.
12. Insert the key into the coded lock cylinder (2) and hold the lock cylinder positioned so the side
with the security plug (3) faces to the left of the key
head.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 6783
13. Hold the ignition lock housing positioned so the security plug actuator lever (3) also faces to the
right of the key head. 14. Push the exposed end of the security plug actuator lever (3) toward the
center of the lock cylinder housing (1) and hold it. Insert the coded lock
cylinder (2) with the key in it into the ignition lock cylinder housing (1) until the cap is flush with the
housing.
15. Rotate the keyed lock cylinder counterclockwise slightly until it stops and detents outward
slightly. The key should be able to be removed and the
lock cylinder should remain in the housing.
16. Install the retaining clip (1) onto the coded lock cylinder where it comes out of the back of the
lock cylinder housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 6784
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Removal Procedure
1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition
Lock Cylinder Replacement). 2. Remove the multifunction turn signal switch housing. Refer to
Multifunction Turn Signal Switch Housing Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch
Housing Replacement).
3. Remove the shear bolt from the ignition lock cylinder case using a hammer and chisel. 4.
Remove the ignition lock cylinder case.
Installation Procedure
1. Install the ignition lock cylinder case.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the ignition lock cylinder case bolt and tighten it until the head shears off. 3. Install the
multifunction turn signal switch. Refer to Multifunction Turn Signal Switch Housing Replacement
(See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch
Housing Replacement).
4. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock
Cylinder Replacement). 5. The passlock sensor is part of the ignition switch. If replacing the ignition
switch, a passlock relearn will be needed. Refer to Control Module
References (See: Testing and Inspection/Programming and Relearning).
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Removal Procedure
1. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
2. Turn the ignition lock cylinder to the accessory position. 3. Insert the 90 degree tip of a pick type
tool into the ignition lock cylinder access hole. 4. Push and hold the ignition lock cylinder retaining
pin down.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 6785
5. Pull the ignition lock cylinder away from the steering column.
Installation Procedure
1. Install the ignition lock cylinder by performing the following procedure:
1. Turn the ignition lock cylinder to the accessory position. 2. Push the ignition lock cylinder in until
the retaining pin locks it in place.
2. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical
Service Bulletins > Locks - Key Code Security Rules and Information
Key: Technical Service Bulletins Locks - Key Code Security Rules and Information
INFORMATION
Bulletin No.: 10-00-89-010
Date: May 27, 2010
Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada
Only)
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior
Saturn and Saab 2002 and Prior Isuzu
Attention:
This bulletin has been created to address potential issues and questions regarding KeyCode
security. This bulletin should be read by all parties involved in KeyCode activity, including dealer
operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin
should be printed and maintained in the parts department for use as a reference.
Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009.
Where Are Key Codes Located?
General Motors provides access to KeyCodes through three sources when a vehicle is delivered to
a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a
small white bar coded tag sent with most new vehicles that also has the key code printed on it.
Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed
on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code
Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers.
The third source for Key codes is through the GM KeyCode Look-Up feature within the
OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model
years from the current model year.
When a vehicle is received by the dealership, care should be taken to safeguard the original
vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have
access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been
completed, the KeyCode information belongs to the customer and General Motors.
Tip
Only the original invoice contains key code information, a re-printed invoice does not.
GM KeyCode Look-Up Application for GM of Canada Dealers
All dealers should review the General Motors of Canada KeyCode Look-Up Policies and
Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates &
keys").
Please note that the KeyCode Access site is restricted. Only authorized users should be using this
application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently
goes back 17 years from current model year.
Important notes about security:
- Users may not access the system from multiple computers simultaneously.
- Users may only request one KeyCode at a time.
- KeyCode information will only be available on the screen for 2 minutes.
- Each user is personally responsible for maintaining and protecting their password.
- Never share your password with others.
- User Id's are suspended after 6 consecutive failed attempts.
- User Id's are disabled if not used for 90 days.
- Processes must be in place for regular dealership reviews.
- The Parts Manager (or assigned management) must have processes in place for employee
termination or life change events. Upon termination individuals access must be turned off
immediately and access should be re-evaluated upon any position changes within the dealership.
- If you think your password or ID security has been breached, contact Dealer Systems Support at
1-800-265-0573.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical
Service Bulletins > Locks - Key Code Security Rules and Information > Page 6790
Each user will be required to accept the following agreement each time the KeyCode application is
used.
Key Code User Agreement
- Key codes are proprietary information belonging to General Motors Corporation and to the vehicle
owner.
- Unauthorized access to, or use of, key code information is unlawful and may subject the user to
criminal and civil penalties.
- This information should be treated as strictly confidential and should not be disclosed to anyone
unless authorized.
I will ensure that the following information is obtained prior to releasing any Key Code information:
1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership.
Registration should have normal markings from the Province that issued the registration and
possibly the
receipt for payment recorded as well.
Important
- GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving
out key codes.
- When the ownership of the vehicle is in doubt, dealership personnel should not provide the
information.
Key code requests should never be received via a fax or the internet and key codes should never
be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the
expected manner that dealers will use to release a key code or as otherwise stipulated in this
bulletin or other materials.
- Key codes should NEVER be sent via a fax or the internet.
- Each Dealership should create a permanent file to document all KeyCode Look Up transactions.
Requests should be filed by VIN and in each folder retain copies of the following:
- Government issued picture ID (Drivers License)
- Registration or other proof of ownership.
- Copy of the paid customer receipt which has the name of the employee who cut and sold the key
to the customer.
- Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up
to either GM or law enforcement officials.
- Dealership Management has the ability to review all KeyCode Look-Up transactions.
- Dealership KeyCode documentation must be retained for two years.
Frequently Asked Questions (FAQs) for GM of Canada Dealers
How do I request a KeyCode for customer owned vehicle that is not registered?
Scrapped, salvaged or stored vehicles that do not have a current registration should still have the
ownership verified by requesting the vehicle title, current insurance policy and / or current lien
holder information from the customers financing source. If you cannot determine if the customer is
the owner of the vehicle, do not provide the key code information. In these cases, a short
description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on
file. Any clarifying explanation should be entered into the comments field.
How do I document a KeyCode request for a vehicle that is being repossessed?
The repossessor must document ownership of the vehicle by providing a court ordered
repossession order and lien-holder documents prior to providing key code information. Copies of
the repossessors Drivers License and a business card should be retained by the dealership for
documentation.
What do I do if the registration information is locked in the vehicle?
Every effort should be made to obtain complete information for each request. Each Dealership will
have to decide on a case by case basis if enough information is available to verify the customer's
ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and
or current lien information from the customers financing source. Dealership Management must be
involved in any request without complete information. If you cannot determine if the customer is the
owner of the vehicle, do not provide the key code information.
Can I get a print out of the information on the screen?
It is important to note that the Key Code Look Up Search Results contain sensitive and/or
proprietary information. For this reason GM recommends against printing it. If the Search Results
must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper
or illegal use.
Who in the dealership has access to the KeyCode application?
Dealership Parts Manager (or assigned management) will determine, and control, who is
authorized to access the KeyCode Look Up application. However, we anticipate that dealership
parts and service management will be the primary users of the application. The KeyCode Look Up
application automatically tracks each user activity session. Information tracked by the system
includes: User name, User ID, all other entered data and the date/time of access.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical
Service Bulletins > Locks - Key Code Security Rules and Information > Page 6791
What if I input the VIN incorrectly?
If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN
or that the VIN has been entered incorrectly) the system will return an error message.
If I am an authorized user for the KeyCode application, can I access the application from home?
Yes.
What if I suspect key code misuse?
Your dealership should communicate the proper procedures for requesting key codes. Any
suspicious activity either within the dealership or externally should be reported to Dealer Systems
Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
Whose key codes can I access through the system?
At this time the following Canadian vehicle codes are available through the system: Chevrolet,
Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu
(up to 2002 model year) for a maximum of 17 model years.
What should I do if I enter a valid VIN and the system does not produce any key code information?
Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This
may be the result of new vehicle information not yet available. In addition, older vehicle information
may have been sent to an archive status. If you do not receive a key code returned for valid VIN,
you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
How do I access KeyCodes if the KeyCode Look-up system is down?
If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling
dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at
1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have
the customer contact Roadside assistance, OnStar if subscribed, or 911.
What should I do if the KeyCode from the look-up system does not work on the vehicle?
On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In
cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting
equipment that the key has been cut correctly. If the key has been cut correctly you may be able to
verify the proper KeyCode was given through the original selling dealer. When unable to verify the
KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at
1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock
cylinder may have been changed. In these situations following the proper SI document for recoding
a key or replacing the lock cylinder may be necessary.
How long do I have to keep KeyCode Records?
Dealership KeyCode documentation must be retained for two years.
Can I get a KeyCode changed in the Look-Up system?
Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed.
Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
What information do I need before I can provide a driver of a company fleet vehicle Keys or
KeyCode information?
The dealership should have a copy of the individual's driver's license, proof of employment and
registration. If there is any question as to the customer's employment by the fleet company, the
dealer should attempt to contact the fleet company for verification. If there is not enough
information to determine ownership and employment, this information should not be provided.
How do I document a request from an Independent Repair facility for a KeyCode or Key?
The independent must provide a copy of their driver's license, proof of employment and signed
copy of the repair order for that repair facility. The repair order must include customer's name,
address, VIN, city, province and license plate number. Copies of this information must be included
in your dealer KeyCode file.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical
Service Bulletins > Locks - Key Code Security Rules and Information > Page 6792
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Locations
Starter Motor: Locations
Powertrain Component Views
Engine - Right Side (LH8)
1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock
Sensor (KS) 2 9 - Starter Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Locations > Page 6796
Starter Motor: Diagrams
Component Connector End Views
Starter X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Locations > Page 6797
Starter Motor: Service and Repair
Starter Motor Replacement (LH8) (5.3L)
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Battery/Battery Cable/Service and
Repair).
2. Remove the right front tire. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair). 3. Remove the engine wiring harness/positive
battery cable terminal nut (4) and cable terminal (5) from the starter. 4. Disconnect the engine
wiring harness electrical connector (2) from the starter motor. 5. Remove the front propeller shaft.
Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller
Shafts, Bearings
and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement).
6. Remove the transmission cover bolt (1).
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7. Remove the starter motor bolts.
8. Unsnap the transmission cover from the starter.
9. Remove the starter heat shield, if required.
10. Remove the starter.
Installation Procedure
1. Install the starter heat shield, if required.
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2. Install the transmission cover to the starter.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Position the starter and install the starter motor bolts.
Tighten the bolts to 50 Nm (37 lb ft).
4. Install the transmission cover bolt (1).
Tighten the bolt to 12 Nm (106 lb in).
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5. Connect the engine wiring harness electrical connector (2) to the starter motor. 6. Install the
engine wiring harness/positive battery cable terminal (5) to the starter and install the nut (4).
Tighten the nut to 9 Nm (80 lb in).
7. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Transmission
and Drivetrain/Drive/Propeller Shafts, Bearings
and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement).
8. Install the right front tire. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair). 9. Lower the vehicle.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Battery/Battery Cable/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information >
Locations
Starter Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Accessory Relay > Component
Information > Locations
Accessory Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Diagrams > Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Auxiliary Power Outlet: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power
Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Diagrams > Diagram Information and Instructions > Page 6929
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Diagrams > Diagram Information and Instructions > Page 6945
6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Diagrams > Diagram Information and Instructions > Page 6951
1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Diagrams > Diagram Information and Instructions > Page 6952
3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Diagrams > Diagram Information and Instructions > Page 6954
7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Diagrams > Diagram Information and Instructions > Page 6976
Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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Component Information > Diagrams > Diagram Information and Instructions > Page 6979
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Diagrams > Diagram Information and Instructions > Page 6980
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Diagrams > Diagram Information and Instructions > Page 6982
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 6983
Auxiliary Power Outlet: Connector Views
Component Connector End Views
Accessory Power Outlet - I/P 1
Accessory Power Outlet - I/P 2 (KC5)
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Auxiliary Power Outlet: Electrical Diagrams
Cigar Lighter/Power Outlet Schematics
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Component Information > Diagrams > Page 6985
Auxiliary Power Outlet: Service and Repair
115-Volt AC Instrument Panel Accessory Power Receptacle Replacement
Tools Required
J 42059 Cigarette Lighter Socket Remover
Removal Procedure
1. Remove the 12 volt power supply or cigar lighter fuse.
2. Remove the socket by placing one side of the "T" portion of the tool J 42059 into the socket and
into the square window tab. 3. Position the opposite "T" portion of the tool into the opposing square
window tab.
4. Pull the socket straight out of the retaining ring. 5. Remove the tool from the socket.
6. Disconnect the electrical connector from the socket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Diagrams > Page 6986
7. Using your finger, remove the socket retaining ring by pulling the retaining ring out of the
mounting hole.
Installation Procedure
1. Position the retaining ring to the mounting hole. 2. Index the key to the retaining ring to the slot in
the mounting hole. 3. Install the retaining ring by pressing the retaining ring into the mounting hole
until fully seated.
4. Connect the electrical connector to the socket.
5. Position the socket to the retaining ring. 6. Install the socket into the retaining ring by pressing in
the socket until fully seated. 7. Install the 12 volt power supply or cigar lighter fuse.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Diagrams > Page 6987
Auxiliary Power Outlet: Tools and Equipment
Special Tools
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest: > 07-08-46-002D > Jul > 09 > Audio System Noise When Using OnStar(R)
Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
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Component Information > Technical Service Bulletins > Customer Interest: > 07-08-46-002D > Jul > 09 > Audio System Noise When Using OnStar(R) > Page 6996
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-46-002D > Jul > 09 > Audio
System - Noise When Using OnStar(R)
Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using
OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-46-002D > Jul > 09 > Audio
System - Noise When Using OnStar(R) > Page 7002
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof
Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Water leaks/ Wind Noise
From The Sunroof
TECHNICAL
Bulletin No.: 07-08-67-001B
Date: June 22, 2009
Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and
Apply Sealer)
Models:
2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof
Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate
Bulletin 07-08-67-001A (Section 08 - Body & Accessories).
Condition
Some customers may comment on water entering into the vehicle from the sunroof area. Other
customers may comment on a wind noise or whistle noise heard from the sunroof area when
driving at different speeds.
Design
The sunroof module is designed to be completely sealed at the roof panel to help prevent water
from traveling past the glass panel seal. The sunroof glass assembly does not have any glass
panel adjustments. The sunroof assembly does not contain a water management drain tube
system. When operating the sunroof, the glass panel moves rearward and slides up above the roof
panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove
excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some
water may enter inside the vehicle.
Cause
Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the
upper sunroof frame assembly.
Wind or Whistle Noise Test Procedure
Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI.
Water Hose Test Procedure
Perform a water hose test to determine where the leak is entering the sunroof assembly.
Important Use a water hose without the nozzle attached at a controlled medium volume water flow.
1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1)
like in the graphic above is not flush, make sure
no parts are broken or missing from the sunroof module assembly.
2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with
warm water to clean the seals. Use GM(TM) Glass
Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks.
3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open
position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6.
Remove the outer trim cover.
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7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8.
Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water
test to verify the leak concern.
10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of
the following four areas:
1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be
entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the
sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip
holder.
11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire
outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking
tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one
inch of tape at a time until the source of the leak can be
pinpointed.
14. Proceed with the water test while removing the masking tape along the right front outer sunroof
frame and roof panel until the complete area has
been tested.
15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame
with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start
water testing while removing the masking tape from the left front corner of the sunroof glass; then
proceed along to the right front corner of
the glass until the complete area has been tested.
18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing
and mark the entry point of the water. 20. The leak could be from more than one area, so
determine which conditions apply and follow the recommended corrections below.
Condition 1
The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof
frame.
Cause 1
The dry foam seal on the upper sunroof frame assembly may have collapsed or has become
distorted, causing the leak.
Correction 1
Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to
the outer edge of the upper sunroof frame using the procedure listed below:
1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI.
Important Note the size, color and locations of the lower sunroof frame screws when removing
them.
2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame.
Important Do Not remove the (red) TORX(R) screws from the track.
3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower
frame from the sunroof module assembly.
Important Have a clean workbench with a flat protective cover. The cover will help protect the
sunroof glass when the glass is placed face down on the bench.
5. Remove the sunroof module and window from the vehicle and place the glass side down on a
clean bench.
Tip The sunroof window can now be manually moved forward or backward.
6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of
the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the
sunroof frame. If the
sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal.
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Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7009
8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if
no adhesive has been used. If adhesive has been
used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner,
P/N 08984, or equivalent, to clean the roof panel.
9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare
edges of the roof panel opening for the sunroof
module. This grease is recommended for use on any bare edges around the sunroof opening. An
acid brush can be used to apply the grease.
10. A caulk gun applicator will be needed to apply the adhesive (1).
Tip You may want to use some disposable gloves to keep the adhesive from getting onto your
hands.
11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame
assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install
the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame
assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Manually push the sunroof window to the full open position. This will allow the window, motors
and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement
in SI. 18. Verify the proper operation of the sunroof.
19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade
while using a 3M(TM) General Purpose Cleaner,
P/N 08984, or equivalent, as shown in the graphic above.
20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover.
Refer to Sunroof Front Trim Cover Replacement in SI.
Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open
the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are
installed properly.
22. Install the outer trim cover and four screws.
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Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7010
Tighten Tighten the screws to 1 Nm (9 lb in).
Condition 2
A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the
window weather seal (4).
Cause 2
The seal on the upper sunroof frame assembly may not have enough sealant under the seal.
Correction 2
Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip
sealing flange located in the upper sunroof frame.
Condition 3
A leak from the sunroof window glass and sunroof window seal.
Cause 3
The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass
to seal properly.
Correction 3
Replace the sunroof window seal following the steps below:
1. Open the sunshade to the full open position.
2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal
Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7011
Condition 4
A leak from around the sunroof glass holder clip, known as a "blow out clip" (1).
Cause 4
A lack of adhesive sealant under the sunroof window holder clip.
Correction 4
Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the
upper frame clip using the steps below.
1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove
the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two
screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the
two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to
the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws.
Tighten Tighten the two screws to 1 Nm (9 lb in).
Important The chamfered edge of the gear goes toward the motor when reinstalling the gear.
10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws.
Tighten Tighten the screw to 2 Nm (18 lb in).
13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install
the sunroof motor assembly. 15. Install the sunroof motor screws and tighten.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim
cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and
four screws.
Tighten Tighten the screws to 1 Nm (9 lb in).
Waterleak Odor in Vehicle
Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles.
Dry out any wet components. Refer to Floor Carpet Drying in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7012
Parts Information
To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144
from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to
place orders. The dealer also has the option to complete a referral request form to purchase the
product through a local supplier.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7018
7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8.
Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water
test to verify the leak concern.
10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of
the following four areas:
1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be
entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the
sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip
holder.
11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire
outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking
tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one
inch of tape at a time until the source of the leak can be
pinpointed.
14. Proceed with the water test while removing the masking tape along the right front outer sunroof
frame and roof panel until the complete area has
been tested.
15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame
with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start
water testing while removing the masking tape from the left front corner of the sunroof glass; then
proceed along to the right front corner of
the glass until the complete area has been tested.
18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing
and mark the entry point of the water. 20. The leak could be from more than one area, so
determine which conditions apply and follow the recommended corrections below.
Condition 1
The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof
frame.
Cause 1
The dry foam seal on the upper sunroof frame assembly may have collapsed or has become
distorted, causing the leak.
Correction 1
Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to
the outer edge of the upper sunroof frame using the procedure listed below:
1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI.
Important Note the size, color and locations of the lower sunroof frame screws when removing
them.
2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame.
Important Do Not remove the (red) TORX(R) screws from the track.
3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower
frame from the sunroof module assembly.
Important Have a clean workbench with a flat protective cover. The cover will help protect the
sunroof glass when the glass is placed face down on the bench.
5. Remove the sunroof module and window from the vehicle and place the glass side down on a
clean bench.
Tip The sunroof window can now be manually moved forward or backward.
6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of
the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the
sunroof frame. If the
sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7019
8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if
no adhesive has been used. If adhesive has been
used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner,
P/N 08984, or equivalent, to clean the roof panel.
9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare
edges of the roof panel opening for the sunroof
module. This grease is recommended for use on any bare edges around the sunroof opening. An
acid brush can be used to apply the grease.
10. A caulk gun applicator will be needed to apply the adhesive (1).
Tip You may want to use some disposable gloves to keep the adhesive from getting onto your
hands.
11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame
assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install
the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame
assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Manually push the sunroof window to the full open position. This will allow the window, motors
and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement
in SI. 18. Verify the proper operation of the sunroof.
19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade
while using a 3M(TM) General Purpose Cleaner,
P/N 08984, or equivalent, as shown in the graphic above.
20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover.
Refer to Sunroof Front Trim Cover Replacement in SI.
Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open
the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are
installed properly.
22. Install the outer trim cover and four screws.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7020
Tighten Tighten the screws to 1 Nm (9 lb in).
Condition 2
A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the
window weather seal (4).
Cause 2
The seal on the upper sunroof frame assembly may not have enough sealant under the seal.
Correction 2
Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip
sealing flange located in the upper sunroof frame.
Condition 3
A leak from the sunroof window glass and sunroof window seal.
Cause 3
The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass
to seal properly.
Correction 3
Replace the sunroof window seal following the steps below:
1. Open the sunshade to the full open position.
2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal
Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7021
Condition 4
A leak from around the sunroof glass holder clip, known as a "blow out clip" (1).
Cause 4
A lack of adhesive sealant under the sunroof window holder clip.
Correction 4
Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the
upper frame clip using the steps below.
1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove
the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two
screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the
two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to
the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws.
Tighten Tighten the two screws to 1 Nm (9 lb in).
Important The chamfered edge of the gear goes toward the motor when reinstalling the gear.
10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws.
Tighten Tighten the screw to 2 Nm (18 lb in).
13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install
the sunroof motor assembly. 15. Install the sunroof motor screws and tighten.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim
cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and
four screws.
Tighten Tighten the screws to 1 Nm (9 lb in).
Waterleak Odor in Vehicle
Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles.
Dry out any wet components. Refer to Floor Carpet Drying in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7022
Parts Information
To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144
from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to
place orders. The dealer also has the option to complete a referral request form to purchase the
product through a local supplier.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > Customer Interest for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No
Crank/No Start
Fuse: Customer Interest Electrical - Dead Battery/No Crank/No Start
TECHNICAL
Bulletin No.: 08-06-03-010
Date: September 30, 2008
Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC)
Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System
Message (Install 125 Amp Mega Fuse)
Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3
Condition
Some customers may comment on the following conditions:
^ The battery runs down.
^ The engine will not crank.
^ The engine will not start.
^ The Instrument Panel Cluster charge indicator turns on.
^ The Driver Information Center displays a Service Charge System message.
Cause
This condition may be caused by an open Mega Fuse in the underhood electrical center.
Correction
Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new
Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently
has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > Customer Interest for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No
Crank/No Start > Page 7031
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead
Battery/No Crank/No Start
Fuse: All Technical Service Bulletins Electrical - Dead Battery/No Crank/No Start
TECHNICAL
Bulletin No.: 08-06-03-010
Date: September 30, 2008
Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC)
Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System
Message (Install 125 Amp Mega Fuse)
Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3
Condition
Some customers may comment on the following conditions:
^ The battery runs down.
^ The engine will not crank.
^ The engine will not start.
^ The Instrument Panel Cluster charge indicator turns on.
^ The Driver Information Center displays a Service Charge System message.
Cause
This condition may be caused by an open Mega Fuse in the underhood electrical center.
Correction
Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new
Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently
has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead
Battery/No Crank/No Start > Page 7037
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block
Fuse: Locations Engine Compartment Fuse Block
ENGINE COMPARTMENT FUSE BLOCK
The engine compartment fuse block is located on the driver side of the engine compartment.
To remove the cover, push in on the tab on the end of the cover and lift. To reinstall the cover, line
up the tab and push down on the cover until the tab clicks into place.
Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the
covers on any electrical component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7040
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7041
The trailer brake relay is located on the bottom side of the battery harness.
FUSES .................................................................................................................................................
..................................................................... USAGE
O2 SNSR ..........................................................................................................................................
Oxygen Sensors, Air Injection Reactor (AIR) Relay A/C
..............................................................................................................................................................
Air Conditioning Control Head, Power Seats A/C CMPRSR ...............................................................
...................................................................................................... Air Conditioning Compressor ABS
.................................................................................................... Antilock Brake System (ABS), ABS
Module, Four-Wheel Drive, Gravity Sensor ABS 1 ..............................................................................
................................................................................................................... ABS 1 (ABS Logic) ABS 2
..............................................................................................................................................................
................................... ABS 2 (ABS Pump) AUX PWR 1 .....................................................................
................................................................................................................... Accessory Power 1 AUX
PWR 2 .................................................................................................................................................
....................................... Accessory Power 2 BCK/UP .......................................................................
.............................................................................................................................. Back-up Lights
BLWR ..................................................................................................................................................
.............................................. Climate Control Fan CLSTR .................................................................
...................................................................................................................................................
Cluster CNSTR VENT .........................................................................................................................
............................................. Fuel Canister Vent Solenoid CRUISE ...............................................
Cruise Control Switch, Inside Rearview Mirror, Transfer Case Control Module, Brake Switch, Clutch
Disable DR/LCK ..................................................................................................................................
....................................... Power Door Locks (If Equipped) DRL .........................................................
................................................................................................................................... Daylight
Running Lamps ERLS .......................................................................................... Mass Air Flow
(MAF) Sensor, Can Purge Solenoid, Air Injector Reactor (AIR) Relay ETC .......................................
...................................................................................................................................... Electronic
Throttle Control (ETC) FOG/LAMP ......................................................................................................
......................................................................... Fog Lamps (If Equipped) FRT PRK LAMP
....................................................................... Front Park/Turn Lamps, Driver and Passenger Side
Power Window Switches Lighting FRT/AXLE .....................................................................................
.................................................................................................... Front Axle Actuator FSCM ..............
..............................................................................................................................................................
....... Fuel System Control Module BACKUP LAMP .............................................................................
............................................................................................................ Backup Lamp HORN ..............
..............................................................................................................................................................
............................................ Horn HTD/SEAT .....................................................................................
.......................................................................................... Heated Seat (If Equipped) IGN
........................................................... Ignition, Clutch Starter Switch, Neutral Safety Back-Up
Switch, Ignition Coils 1-5, Air Conditioning Relay INJ .........................................................................
............................................................................................................................................... Injectors
LT HDLP ..............................................................................................................................................
.......................................... Driver Side Headlamp PCM B ..................................................................
......................................................................................................... Power Control Module (PCM) B
PCMI ....................................................................................................................................................
............................. Power Control Module (PCM) PWR/SEAT
......................................................................................................................................................
Power Seat Circuit Breaker (If Equipped) PWR/WNDW .....................................................................
............................................................................................... Power Windows (If Equipped) RDO ....
..............................................................................................................................................................
........................................................ Radio REAR PRK LAMP
.............................................................................................. Rear Parking Lamp 1, Passenger Side
Taillamp, License Plate Lamps REAR PRK LAMP2 ................ Driver Side Rear Taillamp,
Passenger Side Airbag Indicator Lighting, Instrument Panel Dimming Power (2WD/4WD
switch lighting)
RT HDLP .............................................................................................................................................
..................................... Passenger Side Headlamp RVC ...................................................................
...................................................................................................................... Regulated Voltage
Control S/ROOF ..................................................................................................................................
........................................................ Sunroof (If Equipped) STOP .......................................................
........................................................................................................................................................
Stop Lamps STRTR ............................................................................................................................
............................................................... Starter Solenoid Relay TBC ................................................
............................................................................................................................................... Truck
Body Controller TCM ...........................................................................................................................
........................................................ Transmission Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7042
TCCM ..................................................................................................................................................
.............................. Transfer Case Control Module TRAILER BRAKE ................................................
....................................................................................................................................... Trailer Brake
TRANS ................................................................................................................................................
.......................................... Transmission Solenoid TRN/HAZRD FRT
.....................................................................................................................................
Turn/Hazard/Courtesy/Cargo Lamps/Mirrors TRN/HAZRD REAR ......................................................
............................................................................................................ Rear Turn/Hazard Lights
VSES ...................................................................................................................................................
................. Vehicle Stability Enhancement System WPR ....................................................................
.....................................................................................................................................................
Wiper WSW .........................................................................................................................................
...................................................... Wiper/Washer Switch
RELAYS ..............................................................................................................................................
.................................................................... USAGE
A/C CMPRSR ......................................................................................................................................
............................... Air Conditioning Compressor BEAM SEL ............................................................
................................................................................................................................... Beam Selection
DRL .....................................................................................................................................................
....................................... Daylight Running Lamps FOG/LAMP ..........................................................
..................................................................................................................... Fog Lamps (If Equipped)
BK UP LP ............................................................................................................................................
...................................................... Back Up Lamp HDLP ...................................................................
............................................................................................................................................
Headlamps HORN ...............................................................................................................................
......................................................................................... Horn IGN 3 HVAC
................................................................................................. Ignition 3, Climate Control, Climate
Control Head Fuse, Power Seat Fuse PRK/LAMP
............................................................................................................................................. Front
Parking Lamp Fuse, Rear Parking Lamps PWR/TRN
................................................................................................................ Powertrain, Electronic
Throttle Control Fuse, Oxygen Sensor Fuse RAP
................................................................................ Retained Accessory Power (Power Window
Fuse, Wiper/Washer Switch Fuse), Sunroof Fuse RUN/CRNK ............ Run/Crank, Airbag System
Fuse, Cruise Control Fuse, Ignition Fuse, Back-Up Lamps, ABS Fuse, Front Axle, PCM-1, Injectors
Fuse, Transmission Fuse, ERLS
STRTR .................................................................................................................................................
................................... Starter Relay (PCM Relay) VSES ...................................................................
................................................................................................. Vehicle Stability Enhancement
System WPR .......................................................................................................................................
................................................................. Wipers (On/Off) WPR 2 .....................................................
.......................................................................................................................................... Wiper 2
(High/Low)
MISCELLANEOUS ..............................................................................................................................
................................................................. USAGE
A/C CLTCH ..........................................................................................................................................
....................... Diode -- Air Conditioning, Clutch MEGA FUSE ...........................................................
......................................................................................................................................... Mega Fuse
WPR ....................................................................................................................................................
....................................................... Diode -- Wiper
FUSES .................................................................................................................................................
..................................................................... USAGE
Fuse A .................................................................................................................................................
.................................................. Trailer Park Lamp Fuse B .................................................................
.......................................................................................................... Communication Interface
Module Fuse C .......................................................................................................... Supplemental
Inflatable Restraint System, Sensing and Diagnostic Module Fuse D ................................................
................................................................................................................................... Trailer Auxiliary
Maxi-Fuse
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7043
Fuse: Locations Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7044
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7045
Fuse Block - Underhood - Top View
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7046
Fuse Block - Underhood - Bottom View
Fuse Block - Underhood X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7047
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7048
Fuse Block - Underhood X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7049
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7050
Fuse Block - Underhood X4
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7051
Fuse Block - Underhood X5
Fuse Block - Underhood X6
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7052
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7053
Fuse Block - Underhood X7
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7054
Fuse Block - Underhood X9
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 7055
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Page 7056
Fuse: Application and ID
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Page 7057
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Page 7058
Fuse Block - Underhood - Top View
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Page 7059
Fuse Block - Underhood - Bottom View
Fuse Block - Underhood X1
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Locations > Page 7061
Fuse Block - Underhood X2
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Locations > Page 7063
Fuse Block - Underhood X4
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Fuse Block - Underhood X5
Fuse Block - Underhood X6
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Fuse Block - Underhood X7
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Fuse Block - Underhood X9
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Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Locations > Harness Routing Views
Fuse Block: Locations Harness Routing Views
Harness Routing Views
Forward Lamp Harness Routing
1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn
Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right
11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low
Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body
Harness) 16 - X103 (Forward Lamp Harness to Body Harness)
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17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness
(TT5) 19 - Forward Lamp Harness (-TT5)
Battery Cable Harness Routing
1 - G104 2 - Starter 3 - Generator X2 4 - Battery 5 - G100 6 - Battery Negative Terminal 7 - Fuse
Block - Underhood 8 - Ring Terminal Battery 9 - Ring Terminal Generator 10 - Battery Positive
Terminal 11 - Generator
Body Harness Routing 1 of 3 (Regular Cab)
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1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18
- Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
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1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C
Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Side of the Engine Compartment Components
1 - G104 2 - Starter 3 - Battery 4 - G100 5 - Fuse Block - Underhood 6 - Battery Positive Terminal 7
- Generator
Left and Right Sides of Engine Compartment Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield
Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Fuse Block: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power
Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7174
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7176
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7178
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7179
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7180
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7181
Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7182
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7183
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7187
1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Information > Diagrams > Diagram Information and Instructions > Page 7188
Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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Information > Diagrams > Diagram Information and Instructions > Page 7189
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7190
5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7192
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7193
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7196
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7198
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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Information > Diagrams > Diagram Information and Instructions > Page 7201
6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7202
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7204
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7206
2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7207
4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7208
6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7209
8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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Information > Diagrams > Diagram Information and Instructions > Page 7211
2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7213
4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7214
6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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Information > Diagrams > Diagram Information and Instructions > Page 7233
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 7245
Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 7246
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 7247
Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 7248
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 7249
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information > Diagrams > Diagram Information and Instructions > Page 7250
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 7251
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Page 7252
Fuse Block: Service and Repair
Underhood Electrical Center or Junction Block Replacement
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Battery/Battery Cable/Service and
Repair).
2. Press tabs (1) inward and lift to remove the junction block cover. 3. Remove the fuse relay
center bolts (3) and remove the fuse relay center from the junction block bracket. 4. Pull downward
on the wiring harness ends to remove from the bottom of the fuse relay center.
Installation Procedure
1. Align the wiring harnesses and install the fuse relay center (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Page 7253
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the fuse relay center bolts.
Tighten the relay center bolts to 6 Nm (53 lb in).
3. Install the junction block cover (2). Press downward to engage the tabs.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair
Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7258
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7259
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7260
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7261
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7262
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7263
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D
> Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power
Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced
Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D
> Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 7272
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: >
07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power
Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC
P2138/Reduced Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: >
07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 7278
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199
Multiple Junction Connector: Diagrams X100 - X199
X103
Inline Harness Connector End Views
X103 Forward Lamp Harness to the Body Harness
X104
Inline Harness Connector End Views
X104 Forward Lamp Harness to the Body Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7281
X106
Inline Harness Connector End Views
X106 Body Harness to the Chassis harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7282
X102
Inline Harness Connector End Views
X102 Body Harness to the Chassis Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7283
X107
Inline Harness Connector End Views
X107 Forward Lamp Harness to Right Front Turn Signal Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7284
X108
Inline Harness Connector End Views
X108 Forward Lamp Harness to Left Front Turn Signal Harness
X109
Inline Harness Connector End Views
X109 Engine Harness to Battery Harness (K18)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7285
X110
Inline Harness Connector End Views
X110 Chassis Harness to Engine Harness (UY7)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7286
X125
Inline Harness Connector End Views
X125 Engine Harness to the Body Harness
X126
Inline Harness Connector End Views
X126 Chassis Harness to the Engine Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7287
X175
Inline Harness Connector End Views
X175 Engine Harness to Transmission Harness (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7288
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7289
Multiple Junction Connector: Diagrams X200 - X299
X200
Inline Harness Connector End Views
X200 I/P Harness to the Body Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7290
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7291
X201
Inline Harness Connector End Views
X201 I/P Harness to the Body Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7292
X202
Inline Harness Connector End Views
X202 Driver Door Harness to the Body Harness (AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7293
X203
Inline Harness Connector End Views
X203 I/P Harness to the HVAC Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7294
X204
Inline Harness Connector End Views
X204 Steering Column Harness to the I/P Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7295
X209
Inline Harness Connector End Views
X209 Body Harness to the Driver Door Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7296
X211
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7297
Inline Harness Connector End Views
X211 Passenger Door Harness to the Body Harness (AU3)
X208
Inline Harness Connector End Views
X208 I/P Harness to the Body Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7298
X210
Inline Harness Connector End Views
X210 Body Harness to the Passenger Door Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7299
X275
Inline Harness Connector End Views
X275 SIR Coil Harness to the Body Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7300
X276
Inline Harness Connector End Views
X276 Body Harness to the Steering Column Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7301
Multiple Junction Connector: Diagrams X300 - X399
X307
Inline Harness Connector End Views
X307 Body Harness to the Driver Seat Harness (AG1)
X310
Inline Harness Connector End Views
X310 Dome Lamp Harness to the Body Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7302
X311
Inline Harness Connector End Views
X311 Body Harness to the Right Rear Passenger Door Harness (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7303
X312
Inline Harness Connector End Views
X312 Body Harness to the Left Rear Passenger Door Harness (Extended Cab)
X313
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7304
Inline Harness Connector End Views
X313 Body Harness to the Passenger Seat Harness
X316
Inline Harness Connector End Views
X316 Body Harness to the Left Rear Passenger Door Harness (Crew Cab with A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7305
X316 Body Harness to the Left Rear Passenger Door Harness (Crew Cab without A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7306
X316 Body Harness to the Left Rear Passenger Door Harness (Extended Cab)
X317
Inline Harness Connector End Views
X317 Body Harness to the Right Rear Passenger Door Harness (Crew Cab with A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7307
X317 Body Harness to the Right Rear Passenger Door Harness (Crew Cab without A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7308
X317 Body Harness to the Right Rear Passenger Door Harness (Extended Cab)
X318
Inline Harness Connector End Views
X318 Heat Element to Passenger Seat Harness (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7309
X319
Inline Harness Connector End Views
X319 Heat Element to Driver Seat Harness (AG1)
X320
Inline Harness Connector End Views
X320 Body Harness to Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7310
X314
Inline Harness Connector End Views
X314 Body Harness to the Driver Seat Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7311
X315
Inline Harness Connector End Views
X315 Body Harness to the Passenger Seat Harness (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7312
Multiple Junction Connector: Diagrams X400 - X499
X400
Inline Harness Connector End Views
X400 Chassis Harness to the License Lamp Harness
X403
Inline Harness Connector End Views
X403 Left Rear Lamp Assembly to the Trailer Accessory Harness (Trailer Accessory)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7313
X404
Inline Harness Connector End Views
X404 (UY7) Chassis Harness to License Lamp Harness
X401
Inline Harness Connector End Views
X401 Left Rear Lamp Assembly to the Chassis Harness (- UY7)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7314
X401 Trailer Accessory Harness to the Chassis Harness (UY7)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7315
X402
Inline Harness Connector End Views
X402 Right Rear Lamp Assembly to the Chassis Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 7316
X405
Inline Harness Connector End Views
X405 (UY7) Trailer Jumper Harness to License Lamp Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component
Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place.
3. Remove any connector position assurance (CPA) devices or secondary locks.
Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners
or tape.
4. Separate the relay (1) from the wire harness connector (2).
Installation Procedure
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 7321
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Special Tools
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification
Views (See: Fuse/Application and ID) to locate the electrical center where the relay
exists.
Note: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
3. Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
4. Remove the relay (2) from the electrical center.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 7322
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Accessory Relay > Component Information > Locations
Accessory Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement
(Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component
Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place.
3. Remove any connector position assurance (CPA) devices or secondary locks.
Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners
or tape.
4. Separate the relay (1) from the wire harness connector (2).
Installation Procedure
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement
(Attached to Wire Harness) > Page 7331
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Special Tools
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification
Views (See: Fuse/Application and ID) to locate the electrical center where the relay
exists.
Note: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
3. Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
4. Remove the relay (2) from the electrical center.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement
(Attached to Wire Harness) > Page 7332
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set
By Various Control Modules
Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set
By Various Control Modules > Page 7341
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set
By Various Control Modules > Page 7342
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set
By Various Control Modules > Page 7343
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent
MIL/DTC P2138/Reduced Power
Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent
MIL/DTC P2138/Reduced Power > Page 7348
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10
> Electrical - MIL ON/DTC's Set By Various Control Modules
Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control
Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10
> Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7354
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10
> Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7355
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10
> Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7356
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair
Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair > Page 7361
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair > Page 7362
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair > Page 7363
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair > Page 7364
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair > Page 7365
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair > Page 7366
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10
> Electrical - Intermittent MIL/DTC P2138/Reduced Power
Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced
Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10
> Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 7371
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 >
Electrical - Information For Electrical Ground Repair
Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 >
Electrical - Information For Electrical Ground Repair > Page 7377
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 >
Electrical - Information For Electrical Ground Repair > Page 7378
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 >
Electrical - Information For Electrical Ground Repair > Page 7379
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 >
Electrical - Information For Electrical Ground Repair > Page 7380
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 >
Electrical - Information For Electrical Ground Repair > Page 7381
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 >
Electrical - Information For Electrical Ground Repair > Page 7382
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Accessory Relay > Component Information > Locations
Accessory Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7391
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7392
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7393
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7394
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7395
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7396
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7397
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7398
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7399
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7400
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7401
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7402
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7403
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7404
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7405
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7406
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7407
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7408
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7409
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7410
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7411
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7412
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7413
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7414
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7415
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7416
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7417
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7418
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7419
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7420
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7421
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7422
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7423
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 7424
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Auxiliary Power Outlet: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power
Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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Diagrams > Diagram Information and Instructions > Page 7523
4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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Diagrams > Diagram Information and Instructions > Page 7530
1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
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Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
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1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
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Diagrams > Diagram Information and Instructions > Page 7562
Auxiliary Power Outlet: Connector Views
Component Connector End Views
Accessory Power Outlet - I/P 1
Accessory Power Outlet - I/P 2 (KC5)
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Auxiliary Power Outlet: Electrical Diagrams
Cigar Lighter/Power Outlet Schematics
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Auxiliary Power Outlet: Service and Repair
115-Volt AC Instrument Panel Accessory Power Receptacle Replacement
Tools Required
J 42059 Cigarette Lighter Socket Remover
Removal Procedure
1. Remove the 12 volt power supply or cigar lighter fuse.
2. Remove the socket by placing one side of the "T" portion of the tool J 42059 into the socket and
into the square window tab. 3. Position the opposite "T" portion of the tool into the opposing square
window tab.
4. Pull the socket straight out of the retaining ring. 5. Remove the tool from the socket.
6. Disconnect the electrical connector from the socket.
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7. Using your finger, remove the socket retaining ring by pulling the retaining ring out of the
mounting hole.
Installation Procedure
1. Position the retaining ring to the mounting hole. 2. Index the key to the retaining ring to the slot in
the mounting hole. 3. Install the retaining ring by pressing the retaining ring into the mounting hole
until fully seated.
4. Connect the electrical connector to the socket.
5. Position the socket to the retaining ring. 6. Install the socket into the retaining ring by pressing in
the socket until fully seated. 7. Install the 12 volt power supply or cigar lighter fuse.
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Auxiliary Power Outlet: Tools and Equipment
Special Tools
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio
System - Noise When Using OnStar(R)
Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio
System - Noise When Using OnStar(R) > Page 7575
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 >
Audio System - Noise When Using OnStar(R)
Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using
OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 >
Audio System - Noise When Using OnStar(R) > Page 7581
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service
Bulletins > Customer Interest for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start
Fuse: Customer Interest Electrical - Dead Battery/No Crank/No Start
TECHNICAL
Bulletin No.: 08-06-03-010
Date: September 30, 2008
Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC)
Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System
Message (Install 125 Amp Mega Fuse)
Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3
Condition
Some customers may comment on the following conditions:
^ The battery runs down.
^ The engine will not crank.
^ The engine will not start.
^ The Instrument Panel Cluster charge indicator turns on.
^ The Driver Information Center displays a Service Charge System message.
Cause
This condition may be caused by an open Mega Fuse in the underhood electrical center.
Correction
Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new
Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently
has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service
Bulletins > Customer Interest for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start > Page
7590
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No
Start
Fuse: All Technical Service Bulletins Electrical - Dead Battery/No Crank/No Start
TECHNICAL
Bulletin No.: 08-06-03-010
Date: September 30, 2008
Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC)
Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System
Message (Install 125 Amp Mega Fuse)
Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3
Condition
Some customers may comment on the following conditions:
^ The battery runs down.
^ The engine will not crank.
^ The engine will not start.
^ The Instrument Panel Cluster charge indicator turns on.
^ The Driver Information Center displays a Service Charge System message.
Cause
This condition may be caused by an open Mega Fuse in the underhood electrical center.
Correction
Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new
Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently
has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No
Start > Page 7596
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block
Fuse: Locations Engine Compartment Fuse Block
ENGINE COMPARTMENT FUSE BLOCK
The engine compartment fuse block is located on the driver side of the engine compartment.
To remove the cover, push in on the tab on the end of the cover and lift. To reinstall the cover, line
up the tab and push down on the cover until the tab clicks into place.
Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the
covers on any electrical component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7599
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7600
The trailer brake relay is located on the bottom side of the battery harness.
FUSES .................................................................................................................................................
..................................................................... USAGE
O2 SNSR ..........................................................................................................................................
Oxygen Sensors, Air Injection Reactor (AIR) Relay A/C
..............................................................................................................................................................
Air Conditioning Control Head, Power Seats A/C CMPRSR ...............................................................
...................................................................................................... Air Conditioning Compressor ABS
.................................................................................................... Antilock Brake System (ABS), ABS
Module, Four-Wheel Drive, Gravity Sensor ABS 1 ..............................................................................
................................................................................................................... ABS 1 (ABS Logic) ABS 2
..............................................................................................................................................................
................................... ABS 2 (ABS Pump) AUX PWR 1 .....................................................................
................................................................................................................... Accessory Power 1 AUX
PWR 2 .................................................................................................................................................
....................................... Accessory Power 2 BCK/UP .......................................................................
.............................................................................................................................. Back-up Lights
BLWR ..................................................................................................................................................
.............................................. Climate Control Fan CLSTR .................................................................
...................................................................................................................................................
Cluster CNSTR VENT .........................................................................................................................
............................................. Fuel Canister Vent Solenoid CRUISE ...............................................
Cruise Control Switch, Inside Rearview Mirror, Transfer Case Control Module, Brake Switch, Clutch
Disable DR/LCK ..................................................................................................................................
....................................... Power Door Locks (If Equipped) DRL .........................................................
................................................................................................................................... Daylight
Running Lamps ERLS .......................................................................................... Mass Air Flow
(MAF) Sensor, Can Purge Solenoid, Air Injector Reactor (AIR) Relay ETC .......................................
...................................................................................................................................... Electronic
Throttle Control (ETC) FOG/LAMP ......................................................................................................
......................................................................... Fog Lamps (If Equipped) FRT PRK LAMP
....................................................................... Front Park/Turn Lamps, Driver and Passenger Side
Power Window Switches Lighting FRT/AXLE .....................................................................................
.................................................................................................... Front Axle Actuator FSCM ..............
..............................................................................................................................................................
....... Fuel System Control Module BACKUP LAMP .............................................................................
............................................................................................................ Backup Lamp HORN ..............
..............................................................................................................................................................
............................................ Horn HTD/SEAT .....................................................................................
.......................................................................................... Heated Seat (If Equipped) IGN
........................................................... Ignition, Clutch Starter Switch, Neutral Safety Back-Up
Switch, Ignition Coils 1-5, Air Conditioning Relay INJ .........................................................................
............................................................................................................................................... Injectors
LT HDLP ..............................................................................................................................................
.......................................... Driver Side Headlamp PCM B ..................................................................
......................................................................................................... Power Control Module (PCM) B
PCMI ....................................................................................................................................................
............................. Power Control Module (PCM) PWR/SEAT
......................................................................................................................................................
Power Seat Circuit Breaker (If Equipped) PWR/WNDW .....................................................................
............................................................................................... Power Windows (If Equipped) RDO ....
..............................................................................................................................................................
........................................................ Radio REAR PRK LAMP
.............................................................................................. Rear Parking Lamp 1, Passenger Side
Taillamp, License Plate Lamps REAR PRK LAMP2 ................ Driver Side Rear Taillamp,
Passenger Side Airbag Indicator Lighting, Instrument Panel Dimming Power (2WD/4WD
switch lighting)
RT HDLP .............................................................................................................................................
..................................... Passenger Side Headlamp RVC ...................................................................
...................................................................................................................... Regulated Voltage
Control S/ROOF ..................................................................................................................................
........................................................ Sunroof (If Equipped) STOP .......................................................
........................................................................................................................................................
Stop Lamps STRTR ............................................................................................................................
............................................................... Starter Solenoid Relay TBC ................................................
............................................................................................................................................... Truck
Body Controller TCM ...........................................................................................................................
........................................................ Transmission Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7601
TCCM ..................................................................................................................................................
.............................. Transfer Case Control Module TRAILER BRAKE ................................................
....................................................................................................................................... Trailer Brake
TRANS ................................................................................................................................................
.......................................... Transmission Solenoid TRN/HAZRD FRT
.....................................................................................................................................
Turn/Hazard/Courtesy/Cargo Lamps/Mirrors TRN/HAZRD REAR ......................................................
............................................................................................................ Rear Turn/Hazard Lights
VSES ...................................................................................................................................................
................. Vehicle Stability Enhancement System WPR ....................................................................
.....................................................................................................................................................
Wiper WSW .........................................................................................................................................
...................................................... Wiper/Washer Switch
RELAYS ..............................................................................................................................................
.................................................................... USAGE
A/C CMPRSR ......................................................................................................................................
............................... Air Conditioning Compressor BEAM SEL ............................................................
................................................................................................................................... Beam Selection
DRL .....................................................................................................................................................
....................................... Daylight Running Lamps FOG/LAMP ..........................................................
..................................................................................................................... Fog Lamps (If Equipped)
BK UP LP ............................................................................................................................................
...................................................... Back Up Lamp HDLP ...................................................................
............................................................................................................................................
Headlamps HORN ...............................................................................................................................
......................................................................................... Horn IGN 3 HVAC
................................................................................................. Ignition 3, Climate Control, Climate
Control Head Fuse, Power Seat Fuse PRK/LAMP
............................................................................................................................................. Front
Parking Lamp Fuse, Rear Parking Lamps PWR/TRN
................................................................................................................ Powertrain, Electronic
Throttle Control Fuse, Oxygen Sensor Fuse RAP
................................................................................ Retained Accessory Power (Power Window
Fuse, Wiper/Washer Switch Fuse), Sunroof Fuse RUN/CRNK ............ Run/Crank, Airbag System
Fuse, Cruise Control Fuse, Ignition Fuse, Back-Up Lamps, ABS Fuse, Front Axle, PCM-1, Injectors
Fuse, Transmission Fuse, ERLS
STRTR .................................................................................................................................................
................................... Starter Relay (PCM Relay) VSES ...................................................................
................................................................................................. Vehicle Stability Enhancement
System WPR .......................................................................................................................................
................................................................. Wipers (On/Off) WPR 2 .....................................................
.......................................................................................................................................... Wiper 2
(High/Low)
MISCELLANEOUS ..............................................................................................................................
................................................................. USAGE
A/C CLTCH ..........................................................................................................................................
....................... Diode -- Air Conditioning, Clutch MEGA FUSE ...........................................................
......................................................................................................................................... Mega Fuse
WPR ....................................................................................................................................................
....................................................... Diode -- Wiper
FUSES .................................................................................................................................................
..................................................................... USAGE
Fuse A .................................................................................................................................................
.................................................. Trailer Park Lamp Fuse B .................................................................
.......................................................................................................... Communication Interface
Module Fuse C .......................................................................................................... Supplemental
Inflatable Restraint System, Sensing and Diagnostic Module Fuse D ................................................
................................................................................................................................... Trailer Auxiliary
Maxi-Fuse
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7602
Fuse: Locations Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7603
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7604
Fuse Block - Underhood - Top View
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7605
Fuse Block - Underhood - Bottom View
Fuse Block - Underhood X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7606
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7607
Fuse Block - Underhood X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7608
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7609
Fuse Block - Underhood X4
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7610
Fuse Block - Underhood X5
Fuse Block - Underhood X6
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7611
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7612
Fuse Block - Underhood X7
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7613
Fuse Block - Underhood X9
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block > Page 7614
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7615
Fuse: Application and ID
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7616
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7617
Fuse Block - Underhood - Top View
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7618
Fuse Block - Underhood - Bottom View
Fuse Block - Underhood X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7619
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7620
Fuse Block - Underhood X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7621
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7622
Fuse Block - Underhood X4
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7623
Fuse Block - Underhood X5
Fuse Block - Underhood X6
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7624
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7625
Fuse Block - Underhood X7
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7626
Fuse Block - Underhood X9
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7627
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >
Harness Routing Views
Fuse Block: Locations Harness Routing Views
Harness Routing Views
Forward Lamp Harness Routing
1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn
Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right
11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low
Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body
Harness) 16 - X103 (Forward Lamp Harness to Body Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >
Harness Routing Views > Page 7632
17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness
(TT5) 19 - Forward Lamp Harness (-TT5)
Battery Cable Harness Routing
1 - G104 2 - Starter 3 - Generator X2 4 - Battery 5 - G100 6 - Battery Negative Terminal 7 - Fuse
Block - Underhood 8 - Ring Terminal Battery 9 - Ring Terminal Generator 10 - Battery Positive
Terminal 11 - Generator
Body Harness Routing 1 of 3 (Regular Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >
Harness Routing Views > Page 7633
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18
- Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >
Harness Routing Views > Page 7634
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C
Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >
Harness Routing Views > Page 7635
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >
Harness Routing Views > Page 7636
Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Side of the Engine Compartment Components
1 - G104 2 - Starter 3 - Battery 4 - G100 5 - Fuse Block - Underhood 6 - Battery Positive Terminal 7
- Generator
Left and Right Sides of Engine Compartment Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >
Harness Routing Views > Page 7637
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield
Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 7640
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 7641
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 7642
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 7643
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 7644
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Fuse Block: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power
Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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Diagram Information and Instructions > Page 7719
View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7752
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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Diagram Information and Instructions > Page 7753
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7754
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7755
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7756
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7757
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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Diagram Information and Instructions > Page 7758
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7759
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7760
6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 7761
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7762
2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7763
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7764
6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7765
2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7766
4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7767
6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7768
8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7769
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7770
2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Diagram Information and Instructions > Page 7771
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7772
4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7773
6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7774
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7775
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Diagram Information and Instructions > Page 7776
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7777
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7778
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7779
1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7780
3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7781
5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7782
7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7783
9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7784
11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7785
13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7786
15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 7787
17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7788
19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7789
21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 7790
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 7791
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7792
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7793
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 7794
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 7795
The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
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Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
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1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 7809
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 7810
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page
7811
Fuse Block: Service and Repair
Underhood Electrical Center or Junction Block Replacement
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
2. Press tabs (1) inward and lift to remove the junction block cover. 3. Remove the fuse relay
center bolts (3) and remove the fuse relay center from the junction block bracket. 4. Pull downward
on the wiring harness ends to remove from the bottom of the fuse relay center.
Installation Procedure
1. Align the wiring harnesses and install the fuse relay center (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page
7812
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the fuse relay center bolts.
Tighten the relay center bolts to 6 Nm (53 lb in).
3. Install the junction block cover (2). Press downward to engage the tabs.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair
Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7817
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7818
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7819
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7820
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7821
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7822
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power
Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced
Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power > Page 7831
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 >
Electrical - Intermittent MIL/DTC P2138/Reduced Power
Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC
P2138/Reduced Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 >
Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 7837
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199
Multiple Junction Connector: Diagrams X100 - X199
X103
Inline Harness Connector End Views
X103 Forward Lamp Harness to the Body Harness
X104
Inline Harness Connector End Views
X104 Forward Lamp Harness to the Body Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7840
X106
Inline Harness Connector End Views
X106 Body Harness to the Chassis harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7841
X102
Inline Harness Connector End Views
X102 Body Harness to the Chassis Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7842
X107
Inline Harness Connector End Views
X107 Forward Lamp Harness to Right Front Turn Signal Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7843
X108
Inline Harness Connector End Views
X108 Forward Lamp Harness to Left Front Turn Signal Harness
X109
Inline Harness Connector End Views
X109 Engine Harness to Battery Harness (K18)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7844
X110
Inline Harness Connector End Views
X110 Chassis Harness to Engine Harness (UY7)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7845
X125
Inline Harness Connector End Views
X125 Engine Harness to the Body Harness
X126
Inline Harness Connector End Views
X126 Chassis Harness to the Engine Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7846
X175
Inline Harness Connector End Views
X175 Engine Harness to Transmission Harness (M30)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7847
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7848
Multiple Junction Connector: Diagrams X200 - X299
X200
Inline Harness Connector End Views
X200 I/P Harness to the Body Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7849
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7850
X201
Inline Harness Connector End Views
X201 I/P Harness to the Body Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7851
X202
Inline Harness Connector End Views
X202 Driver Door Harness to the Body Harness (AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7852
X203
Inline Harness Connector End Views
X203 I/P Harness to the HVAC Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7853
X204
Inline Harness Connector End Views
X204 Steering Column Harness to the I/P Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7854
X209
Inline Harness Connector End Views
X209 Body Harness to the Driver Door Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7855
X211
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7856
Inline Harness Connector End Views
X211 Passenger Door Harness to the Body Harness (AU3)
X208
Inline Harness Connector End Views
X208 I/P Harness to the Body Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7857
X210
Inline Harness Connector End Views
X210 Body Harness to the Passenger Door Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7858
X275
Inline Harness Connector End Views
X275 SIR Coil Harness to the Body Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7859
X276
Inline Harness Connector End Views
X276 Body Harness to the Steering Column Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7860
Multiple Junction Connector: Diagrams X300 - X399
X307
Inline Harness Connector End Views
X307 Body Harness to the Driver Seat Harness (AG1)
X310
Inline Harness Connector End Views
X310 Dome Lamp Harness to the Body Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7861
X311
Inline Harness Connector End Views
X311 Body Harness to the Right Rear Passenger Door Harness (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7862
X312
Inline Harness Connector End Views
X312 Body Harness to the Left Rear Passenger Door Harness (Extended Cab)
X313
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7863
Inline Harness Connector End Views
X313 Body Harness to the Passenger Seat Harness
X316
Inline Harness Connector End Views
X316 Body Harness to the Left Rear Passenger Door Harness (Crew Cab with A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7864
X316 Body Harness to the Left Rear Passenger Door Harness (Crew Cab without A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7865
X316 Body Harness to the Left Rear Passenger Door Harness (Extended Cab)
X317
Inline Harness Connector End Views
X317 Body Harness to the Right Rear Passenger Door Harness (Crew Cab with A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7866
X317 Body Harness to the Right Rear Passenger Door Harness (Crew Cab without A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7867
X317 Body Harness to the Right Rear Passenger Door Harness (Extended Cab)
X318
Inline Harness Connector End Views
X318 Heat Element to Passenger Seat Harness (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7868
X319
Inline Harness Connector End Views
X319 Heat Element to Driver Seat Harness (AG1)
X320
Inline Harness Connector End Views
X320 Body Harness to Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7869
X314
Inline Harness Connector End Views
X314 Body Harness to the Driver Seat Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7870
X315
Inline Harness Connector End Views
X315 Body Harness to the Passenger Seat Harness (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7871
Multiple Junction Connector: Diagrams X400 - X499
X400
Inline Harness Connector End Views
X400 Chassis Harness to the License Lamp Harness
X403
Inline Harness Connector End Views
X403 Left Rear Lamp Assembly to the Trailer Accessory Harness (Trailer Accessory)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7872
X404
Inline Harness Connector End Views
X404 (UY7) Chassis Harness to License Lamp Harness
X401
Inline Harness Connector End Views
X401 Left Rear Lamp Assembly to the Chassis Harness (- UY7)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7873
X401 Trailer Accessory Harness to the Chassis Harness (UY7)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7874
X402
Inline Harness Connector End Views
X402 Right Rear Lamp Assembly to the Chassis Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 7875
X405
Inline Harness Connector End Views
X405 (UY7) Trailer Jumper Harness to License Lamp Harness
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information >
Service and Repair > Relay Replacement (Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component
Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place.
3. Remove any connector position assurance (CPA) devices or secondary locks.
Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners
or tape.
4. Separate the relay (1) from the wire harness connector (2).
Installation Procedure
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information >
Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 7880
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Special Tools
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification
Views (See: Fuse/Application and ID) to locate the electrical center where the relay
exists.
Note: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
3. Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
4. Remove the relay (2) from the electrical center.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information >
Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 7881
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Accessory Relay > Component Information > Locations
Accessory Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component
Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place.
3. Remove any connector position assurance (CPA) devices or secondary locks.
Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners
or tape.
4. Separate the relay (1) from the wire harness connector (2).
Installation Procedure
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness)
> Page 7890
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Special Tools
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification
Views (See: Fuse/Application and ID) to locate the electrical center where the relay
exists.
Note: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
3. Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
4. Remove the relay (2) from the electrical center.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness)
> Page 7891
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control
Modules
Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control
Modules > Page 7900
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control
Modules > Page 7901
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control
Modules > Page 7902
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced
Power
Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced
Power > Page 7907
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL
ON/DTC's Set By Various Control Modules
Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control
Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL
ON/DTC's Set By Various Control Modules > Page 7913
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL
ON/DTC's Set By Various Control Modules > Page 7914
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL
ON/DTC's Set By Various Control Modules > Page 7915
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair
Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair > Page 7920
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair > Page 7921
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair > Page 7922
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair > Page 7923
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair > Page 7924
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair > Page 7925
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent
MIL/DTC P2138/Reduced Power
Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced
Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent
MIL/DTC P2138/Reduced Power > Page 7930
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair
Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 7936
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 7937
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 7938
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 7939
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 7940
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 7941
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications
Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications
WARRANTY ADMINISTRATION
Bulletin No.: 05-03-07-009C
Date: December 09, 2010
Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks
Supercede: This bulletin is being extensively revised to provide technicians and warranty
administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF
WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT
SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension).
Purpose
The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors'
warranty service requirements and recommendations for customer concerns related to wheel
alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel
Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty
service.
Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING
YOUR NEXT GM WHEEL ALIGNMENT SERVICE.
The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a
successful wheel alignment service.
1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension
and steering configurations. Vehicles
modified in any of these areas are not covered for wheel alignment warranty.
2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is
within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for
labor operations E2000 and E2020.
The following information must be documented or attached to the repair order:
- Customer concern in detail
- What corrected the customer concern?
- If a wheel alignment is performed:
- Consult SI for proper specifications.
- Document the "Before" AND "After" wheel alignment measurements/settings.
- Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin)
5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the
appropriate calibration maintenance schedules.
Important If it is determined that a wheel alignment is necessary under warranty, use the proper
labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel
Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for
other component repairs is to be charged to the component that causes a wheel alignment
operation.).
The following flowchart is to help summarize the information detailed in this bulletin and should be
used whenever a wheel alignment is performed.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 7947
Verify Original Equipment Condition of the Vehicle
- Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are
on the vehicle.
- Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have
NOT been done to the vehicle.
- Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision
damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles,
suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact.
- Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving
may show up by looking at the tires and condition of the vehicle.
- Check for other additional equipment items that may significantly affect vehicle mass such as
large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in
trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and
wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed
semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of
these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with
equipment such as the above.)
Customer Concerns, "Normal Operation" Conditions and "Mileage Policy"
Possible Concerns
The following are typical conditions that may require wheel alignment warranty service:
1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of
effort required at the steering wheel to maintain the
vehicle's straight heading."
Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle
Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull
concerns can be due to road crown or road slope, tires, wheel alignment or even in rare
circumstances a steering gear issue. Lead/pull concerns due to road crown are considered
"Normal Operation" and are NOT a warrantable condition -- the customer should be advised that
this is "Normal Operation."
Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a
level condition. If so, this is more likely a "steering wheel angle" concern because the customer is
"steering" the vehicle to obtain a "level" steering wheel.
2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined
as the steering wheel angle (clocking)
deviation from "level" while maintaining a straight heading on a typical straight road.
3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the
shoulders of tires is NOT considered unusual and
should even out with a tire rotation; if the customer is concerned about a "feathering" condition of
the tires, the customer could be advised to rotate the tires earlier than the next scheduled
mileage/maintenance interval (but no later than the next interval). Be sure to understand the
customer's driving habits as this will also heavily influence the tire wear performance; tire wear from
aggressive or abusive driving habits is NOT a warrantable condition.
Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is
"normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can
show evidence of feathering from the factory. These issues do NOT affect the overall performance
and tread life of the tire. Dealer personnel should always check the customer's maintenance
records to ensure that tire inflation pressure is being maintained to placard and that the tires are
being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be
performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 7948
Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center
Ribs
Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder
Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear
Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear
Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the
repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center
wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF,
LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life,
etc. A field product report with pictures of the tire wear condition is recommended. Refer to
Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C.
4. Other repairs that affect wheel alignment; e.g., certain component replacement such as
suspension control arm replacement, engine cradle
adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock,
steering knuckle, etc. may require a wheel alignment.
Important If other components or repairs are identified as affecting the wheel alignment, policy calls
for the wheel alignment labor time to be charged to the replaced/repaired component's labor
operation time rather than the wheel alignment labor operations.
Important Vibration type customer concerns are generally NOT due to wheel alignment except in
the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are
NOT to be performed as an investigation/correction for vibration concerns.
"Normal Operation" Conditions
Vehicle Lead/Pull Due to Road Crown or Slope:
As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope.
Be sure to verify from the customer the types of roads they are driving as they may not recognize
the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires
significant steering effort to prevent it from "climbing" the road crown there may be an issue to be
looked into further.
Important
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 7949
A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within
"Normal Operation."
Mileage Policy
The following mileage policy applies for E2020 and E2000 labor operations: Note
Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana
Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing
the vehicles.
- 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to
the tie down during shipping, the vehicle's suspension requires some time to reach normal
operating position. For this reason, new vehicles are generally NOT to be aligned until they have
accumulated at least 800 km (500 mi). A field product report should accompany any claim within
this mileage range.
- 801-12,000 km (501-7,500 mi):
- If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle
steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be
apparent early in the life of the vehicle. The following policy applies:
- Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT,
Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and
Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required
- All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above:
E2000/E2020 Claims: Dealer Service Manager Authorization Required
- 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible
for the wheel alignment expense or dealers may provide on a case-by case basis a one-time
customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component
required the use of the subject labor operations, the identified defective component labor operation
will include the appropriate labor time for a wheel alignment as an add condition to the component
repair.
Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN.
Warranty Documentation Requirements
When a wheel alignment service has been deemed necessary, the following items will need to be
clearly documented on/with the repair order:
- Customer concern in detail
- What corrected the customer concern?
- If a wheel alignment is performed:
- Consult SI for proper specifications.
- Document the "Before" AND "After" wheel alignment measurements/settings.
- Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin)
1. Document the customer concern in as much detail as possible on the repair order and in the
warranty administration system. Preferred examples:
- Steering wheel is off angle in the counterclockwise direction by approximately x degrees or
clocking position.
- Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe,
Moderate or Slight.
- RF and LF tires are wearing on the outside shoulders with severe feathering.
Important In the event of a lead/pull or steering wheel angle concern, please note the direction of
lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the
repair order and within the warranty claim verbatim.
Important In the event of a tire wear concern, please note the position on the vehicle and where the
wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder.
2. Document the technician's findings on cause and correction of the issue. Examples:
- Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees
to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees.
- Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of
+0.30 degrees to 0.00 degrees on the vehicle.
- Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees.
3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the
Repair Order or if print-out capability is not
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 7950
available, measurements may also be clearly and legibly handwritten into the Wheel Alignment
Repair Order Questionnaire attached to this bulletin.
4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of
"Before" and "After" wheel alignment measurements to
the Repair Order and retain for use by GM.
Wheel Alignment Equipment and Process
Wheel alignments must be performed with a quality machine that will give accurate results when
performing checks. "External Reference" (image-based camera technology) is preferred. Please
refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment
Requirements and Recommendations.
Requirements:
- Computerized four wheel alignment system.
- Computer capable of printing before and after alignment reports.
- Computer capable of time and date stamp printout.
- Racking system must have jacking capability
- Racking system must be capable of level to 1.6 mm (1/16 in)
- Appropriate wheel stops and safety certification
- Built-in turn plates and slip plates
- Wheel clamps capable of attaching to 20" or larger wheels
- Racking capable of accepting any GM passenger car or light duty truck
- Operator properly trained and ASE-certified (U.S. only) in wheel alignment
Recommendations:
Racking should have front and rear jacking capability.
Equipment Maintenance and Calibration:
Alignment machines must be regularly calibrated in order to give correct information. Most
manufacturers recommend the following:
- Alignment machines with "internal reference" sensors should be checked (and calibrated, if
necessary) every six months.
- Alignment machines with "external reference" (image-based camera technology) should be
checked (and calibrated, if necessary) once a year.
- Racks must be kept level to within 1.6 mm (1/16 in).
- If any instrument that is part of the alignment machine is dropped or damaged in some way,
check the calibration immediately.
Check with the manufacturer of your specific equipment for their recommended service/calibration
schedule.
Wheel Alignment Process
When performing wheel alignment measurement and/or adjustment, the following steps should be
taken:
Preliminary Steps:
1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels
and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4.
Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for
looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to
stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate
for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI).
Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the
wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the
specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads,
such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's
instructions.
Measure/Adjust:
Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify
that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date
by comparing these to the wheel alignment specifications for the appropriate model and model year
in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments,
irregular and/or premature tire wear and repeat customer concerns
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 7951
Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear
wheel alignment angles first in order to obtain proper front wheel alignment angles.
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front
and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment
angles and record the readings.
If necessary, adjust the wheel alignment to vehicle specification and record the before and after
measurements. Refer to Wheel Alignment Specifications in SI.
Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only
source of GM wheel alignment specifications that is kept up-to-date throughout the year.
Test drive vehicle to ensure proper repair.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 7952
Frame Angle Measurement (Express / Savana Only) ........
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 7953
What corrected the customer concern and was the repair verified?
Please Explain: .............
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Fastener
Tightening Specifications
Alignment: Specifications Fastener Tightening Specifications
Fastener Tightening Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Fastener
Tightening Specifications > Page 7956
Alignment: Specifications Trim Height Specifications
Trim Height Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Fastener
Tightening Specifications > Page 7957
Alignment: Specifications Wheel Alignment Specifications
Wheel Alignment Specifications
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Caster Description
Alignment: Description and Operation Caster Description
Caster Description
Caster is the tilting of the uppermost point of the steering axis either forward or backward, when
viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-).
Caster influences directional control of the steering but does not affect the tire wear. Caster is
affected by the vehicle height, therefore it is important to keep the body at its designed height.
Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the
vehicle is lower than its designated trim height, the front suspension moves to a more positive
caster. If the rear of the vehicle is higher than its designated trim height, the front suspension
moves to a less positive caster.
With too little positive caster, steering may be touchy at high speed and wheel returnability may be
diminished when coming out of a turn. If one wheel has more positive caster than the other, that
wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead
to the side with the least amount of positive caster.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Caster Description > Page 7960
Alignment: Description and Operation Camber Description
Camber Description
Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle.
When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at
the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical.
Camber settings influence the directional control and the tire wear.
Too much positive camber will result in premature wear on the outside of the tire and cause
excessive wear on the suspension parts.
Too much negative camber will result in premature wear on the inside of the tire and cause
excessive wear on the suspension parts.
Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side
with the most positive camber.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Caster Description > Page 7961
Alignment: Description and Operation Toe Description
Toe Description
Toe is a measurement of how much the front and/or rear wheels are turned in or out from a
straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the wheels roll parallel.
Toe also offsets the small deflections of the wheel support system that occur when the vehicle is
rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the
wheels tend to roll parallel on the road when the vehicle is moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Caster Description > Page 7962
Alignment: Description and Operation Setback Description
Setback Description
Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may
be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The
first clue is a caster difference from side-to-side of more than 1 degree.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Caster Description > Page 7963
Alignment: Description and Operation
Caster Description
Caster Description
Caster is the tilting of the uppermost point of the steering axis either forward or backward, when
viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-).
Caster influences directional control of the steering but does not affect the tire wear. Caster is
affected by the vehicle height, therefore it is important to keep the body at its designed height.
Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the
vehicle is lower than its designated trim height, the front suspension moves to a more positive
caster. If the rear of the vehicle is higher than its designated trim height, the front suspension
moves to a less positive caster.
With too little positive caster, steering may be touchy at high speed and wheel returnability may be
diminished when coming out of a turn. If one wheel has more positive caster than the other, that
wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead
to the side with the least amount of positive caster.
Camber Description
Camber Description
Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle.
When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at
the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical.
Camber settings influence the directional control and the tire wear.
Too much positive camber will result in premature wear on the outside of the tire and cause
excessive wear on the suspension parts.
Too much negative camber will result in premature wear on the inside of the tire and cause
excessive wear on the suspension parts.
Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side
with the most positive camber.
Toe Description
Toe Description
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Caster Description > Page 7964
Toe is a measurement of how much the front and/or rear wheels are turned in or out from a
straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the wheels roll parallel.
Toe also offsets the small deflections of the wheel support system that occur when the vehicle is
rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the
wheels tend to roll parallel on the road when the vehicle is moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.
Setback Description
Setback Description
Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may
be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The
first clue is a caster difference from side-to-side of more than 1 degree.
Thrust Angles Description
Thrust Angles Description
The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action
relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the
thrust angle is geometrically aligned with the body centerline (2).
In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The
resulting deviation from the centerline is the thrust angle.
Lead/Pull Description
Lead/Pull Description
At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at
the steering wheel to maintain the vehicle's straight
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Caster Description > Page 7965
path.
Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal
operation.
Lead/pull is usually caused by the following factors:
* Road slope
* Variability in tire construction
* Wheel alignment (front cross caster and camber)
* Unbalanced steering gear
* Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if
equipped.
Wander Description
Wander Description
Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with
hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external
disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel.
Scrub Radius Description
Scrub Radius Description
Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the
tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the
SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle
to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller
the scrub radius, the better the directional stability. Installing aftermarket wheels that have
additional offset will dramatically increase the scrub radius. The newly installed wheels may cause
the centerline of the tires to move further away from the spindle. This will increase the scrub radius.
A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive
vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub
radius is not directly measurable by the conventional methods. Scrub radius is projected
geometrically by engineers during the design phase of the suspension.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Page 7966
Alignment: Testing and Inspection
Trim Height Inspection
Trim Height Measurements
Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights
can cause bottoming out over bumps, damage to the suspension components and symptoms
similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns
and before checking the wheel alignment. Perform the following before measuring the trim heights.
1. Make sure that the vehicle is on a level surface, such as an alignment rack. 2. Remove the
alignment rack floating pins. 3. Set the tire pressure to the pressures shown on the certification
label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID
Label (See: Application and ID).
4. Check the fuel level. Add additional weight if necessary to simulate a full tank. 5. Make sure that
the rear compartment is empty except for the spare tire. 6. Close the doors and he hood.
Z Height Measurement
The Z height dimension measurement determines the proper ride height for the front end of the
vehicle. Vehicles equipped with torsion bars use an adjusting arm in order to adjust the Z height
dimension. Vehicles without torsion bars have no adjustment and could require replacement of
suspension components. Jounce the front and rear suspension to obtain at least 38 mm (1.5 in)
deflection, then allow the vehicle to settle.
Important: The left and right Z height difference should be no more than 12 mm (0.47 in).
1. Set the top edge of the level on the reference surface (Point A) of the steering knuckle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Page 7967
2. With the level on the steering knuckle (C), extend the level directly under the rear of the rear of
the front attachment bolt of the lower control arm
(A).
3. While keeping the level in contact with the knuckle reference surface, adjust the level up or down
until the bubble indicates it is horizontally level. 4. Extend a tape measure straight down from the
center of the attachment bolt. The point where the tape measure and the level intersect is your first
measurement.
5. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the
level directly under the front end of the rear
attachment bolt of the lower control arm (B).
6. Extend a tape measure straight down from the center of the attachment bolt. The point where
the tape measure and the level intersect is your
second measurement.
7. Average the 2 readings (add them together, and then divide by 3) and this result is your final Z
height number. 8. Repeat steps 1 through 7, a total of 3 times, writing down the results. 9. Average
the results (add them together, and then divide by 3) and this result is your final Z height number.
10. Compare your Z height number with the Service Information Z height specification. Refer to
Trim Height Specifications (See:
Suspension/Specifications/Trim Height Specifications).
Z Height Adjustment
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Page 7968
1. For vehicles equipped with a torsion bar suspension turn the torsion bar adjuster bolt (1)
clockwise to raise the and counterclockwise to lower the
height adjustment.
2. For vehicles without torsion bars, replace damaged or worn components as necessary.
D Height Measurement
Important: The left and right D height difference should be no more than 12 mm (0.47 in.)
1. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let
the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. D Height shall be
measured as the perpendicular distance from the inside lip of the jounce bumper cup flange to the
jounce bumper contact pad, or
top of the rear axle "tube" when a jounce bumper pad is not used.
5. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 6. Gently remove your hands and let
the vehicle settle. 7. Repeat this operation 2 more times for a total of 3 times. 8. Re-measure the D
height as in step 4. 9. The true D height is the average of the measurement from step 4 and step 8.
Refer to Trim Height Specifications (See:
Suspension/Specifications/Trim Height Specifications).
10. If these measurements are out of specifications, inspect for the following conditions:
* Worn or damaged suspension components
* Collision damage
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement
Alignment: Service and Repair Wheel Alignment Measurement
Wheel Alignment Measurement
Steering and vibration complaints are not always the result of improper alignment. One possible
cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly
manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical
straight road, lead/pull is the amount of effort required at the steering wheel to maintain the
vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without
pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and
Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull
Correction) in order to determine if the vehicle has a tire lead problem.
Before performing any adjustment affecting wheel alignment, perform the following inspections and
adjustments in order to ensure correct alignment readings:
* Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire
Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID) and Tire Diagnosis Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related
Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear).
* Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications
(See: Testing and Inspection/Symptom Related Diagnostic Procedures/Vibration Diagnosis and
Correction/Specifications/Tire and Wheel Runout Specifications).
* Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis
(See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel
Bearings Diagnosis).
* Inspect the ball joints for looseness or wear.
* Inspect the tie rod ends for looseness or wear.
* Inspect the control arms and stabilizer shaft for looseness or wear.
* Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications
(See: Steering/Specifications).
* Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to
Suspension Strut and Shock Absorber Testing - On Vehicle (See: Suspension/Testing and
Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber
Testing - On Vehicle).
* Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Suspension/Testing and
Inspection/Component Tests and General Diagnostics/Trim Height Inspection).
* Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or
suspension components.
* Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load
added.
Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in
the vehicle, these items should remain in the vehicle during alignment adjustments. Give
consideration also to the condition of the equipment being used for the alignment. Follow the
equipment manufacturer's instructions.
Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the
setting exceeds the service allowable specifications, correct the alignment to the service preferred
specifications. Refer to Wheel Alignment Specifications (See: Specifications).
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front
and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment
angles and record the readings.
Note: *
Record the "Before" and "After" alignment measurements.
* When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel
alignment angles first in order to obtain proper front alignment angles.
4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment
Specifications (See: Specifications).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement > Page 7971
Alignment: Service and Repair Front Caster and Camber Adjustment
Front Caster and Camber Adjustment
Special Tools
J 45938 Alignment Socket
1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the
slotted frame bracket in order to reposition the
control arm. Note: Before adjusting the caster and camber angles, jounce the front bumper three
times to allow the vehicle to return to normal height.
Measure and adjust the caster and the camber with the vehicle at curb height. The front
suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Specifications (See:
Suspension/Specifications/Trim Height Specifications).
For an accurate reading, do not push or pull on the tires during the alignment process.
2. Determine the caster angle (2). Be sure to compensate for frame angle where required.
3. Determine the positive camber (2) or negative camber (3) angle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement > Page 7972
4. The 4WD and 2WD Z71 vehicles are adjusted at the upper control arm.
5. The 2WD vehicles are adjusted at the lower control arm. 6. Remove the pinned adjusting cam
insert. Do not reinstall the cam insert. 7. Loosen the control arm cam adjustment bolts.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
8. Using the J 45938 adjust the caster and the camber angle by turning the cam bolts until the
specifications have been met.
When the adjustments are complete, hold the cam bolt in order to ensure the cam bolt position
does not change while tightening the nut.
* Tighten the 2WD cam nuts to 155 Nm (114 lb ft).
* Tighten the 4WD cam nuts to 155 Nm (114 lb ft).
9. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment
Specifications (See: Specifications).
When the caster and camber are within specifications, adjust the toe. Refer to Wheel Alignment Steering Wheel Angle and/or Front Toe Adjustment (See: Wheel Alignment - Steering Wheel Angle
and/or Front Toe Adjustment).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement > Page 7973
Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe
Adjustment
Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment
1. Loosen the jam nut on the tie rod. 2. Rotate the inner tie rod to the required toe specification
setting. Refer to Wheel Alignment Specifications (See: Specifications).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the jam nut on the tie rod to 70 Nm (52 lb ft). 4. Check the toe setting after tightening. 5.
Re-adjust the toe setting if necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Page
7974
Alignment: Tools and Equipment
Special Tools
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service
Bulletins > Tire Monitor System - TPM Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams
Steering Angle Sensor: Diagrams
Component Connector End Views
Steering Wheel Position Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft
Lower Bearing Replacement
Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 7992
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering
Steering Wheel Position Sensor Centering
Removal Procedure
Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE
removing the sensor from the steering column. Once you have identified the steering wheel
position sensor, follow the instructions listed in the removal procedure.
1. Verify the type of steering wheel position sensor.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right.
Important: If reusing the existing sensor, you do not have to align the sensor before removal.
Centering is not required when it is time to reinstall.
3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing
assembly. 5. To install the sensor, proceed to step 1 in the installation section.
6. From the technicians point of view, the FRONT of the sensor will have:
* A foam ring (2)
* A pin hole (1) for centering the pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff
(3) before removing the sensor. Failure to do so will cause misalignment when installing the
sensor. A new sensor will be required if misaligned.
7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the
sensor. 9. Remove the sensor from the adapter and bearing assembly.
10. To install the sensor, proceed to step 5 in the installation procedure.
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Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 7993
11. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note the location of the pin hole.
12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing
assembly. 14. To install the sensor, proceed to step 9 in the installation procedure.
15. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note location of the pin hole.
* A sensor clip in FRONT of the sensor
16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18.
Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to
step 13 in the installation procedure.
20. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (3)
* A pin hole (1) for the centering pin-Note the location of the pin hole.
* An alignment mark (2) on the flush rotor flange cuff (3) for installation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 7994
21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing
assembly. 23. To install the sensor, proceed to step 17 in the installation procedure.
24. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (4)
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* An alignment mark (3) on the flush rotor flange cuff (4) for installation
* A foam ring (1)
25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing
assembly. 27. To install the sensor, proceed to step 21 in the installation procedure.
Installation Procedure
Important: If reusing the existing sensor, no centering of the sensor is required.
1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin
until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1)
connector will be on your right.
From the technicians point of view, the BACK of the sensor (2) connector will be on your left.
3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 4. Install the connector to the sensor.
5. From the technicians point of view, the FRONT of the sensor will have:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 7995
* A foam ring (4)
* A pin hole (7) for the centering pin-Note the location of the pin hole.
* A flushed rotor flange cuff (6)
* An alignment mark (5) for installation
6. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* A foam ring (3)
* An alignment tab (2) for installing into the adapter and bearing assembly
* A view of the inside of the connector
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 8. Install the connector to the sensor.
9. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A raised rotor flange cuff (5)
* An alignment mark (4) for installation
10. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 12. Install the connector to the sensor.
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Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 7996
13. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A raised rotor flange cuff (4)
* An alignment mark (3) for installation
14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 16. Install the connector to the sensor.
17. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
* An alignment mark (3) for installation
18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 20. Install the connector to the sensor.
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Sensor or Steering Shaft Lower Bearing Replacement > Page 7997
21. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A flush rotor flange cuff (5)
* An alignment mark (4) for installation
* A foam ring (6)
22. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 24. Install the connector to the sensor.
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Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams
Steering Angle Sensor: Diagrams
Component Connector End Views
Steering Wheel Position Sensor
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and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel
Position Sensor or Steering Shaft Lower Bearing Replacement
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft
Lower Bearing Replacement
Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel
Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8004
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering
Steering Wheel Position Sensor Centering
Removal Procedure
Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE
removing the sensor from the steering column. Once you have identified the steering wheel
position sensor, follow the instructions listed in the removal procedure.
1. Verify the type of steering wheel position sensor.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right.
Important: If reusing the existing sensor, you do not have to align the sensor before removal.
Centering is not required when it is time to reinstall.
3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing
assembly. 5. To install the sensor, proceed to step 1 in the installation section.
6. From the technicians point of view, the FRONT of the sensor will have:
* A foam ring (2)
* A pin hole (1) for centering the pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff
(3) before removing the sensor. Failure to do so will cause misalignment when installing the
sensor. A new sensor will be required if misaligned.
7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the
sensor. 9. Remove the sensor from the adapter and bearing assembly.
10. To install the sensor, proceed to step 5 in the installation procedure.
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Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8005
11. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note the location of the pin hole.
12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing
assembly. 14. To install the sensor, proceed to step 9 in the installation procedure.
15. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note location of the pin hole.
* A sensor clip in FRONT of the sensor
16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18.
Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to
step 13 in the installation procedure.
20. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (3)
* A pin hole (1) for the centering pin-Note the location of the pin hole.
* An alignment mark (2) on the flush rotor flange cuff (3) for installation
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and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel
Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8006
21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing
assembly. 23. To install the sensor, proceed to step 17 in the installation procedure.
24. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (4)
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* An alignment mark (3) on the flush rotor flange cuff (4) for installation
* A foam ring (1)
25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing
assembly. 27. To install the sensor, proceed to step 21 in the installation procedure.
Installation Procedure
Important: If reusing the existing sensor, no centering of the sensor is required.
1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin
until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1)
connector will be on your right.
From the technicians point of view, the BACK of the sensor (2) connector will be on your left.
3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 4. Install the connector to the sensor.
5. From the technicians point of view, the FRONT of the sensor will have:
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Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8007
* A foam ring (4)
* A pin hole (7) for the centering pin-Note the location of the pin hole.
* A flushed rotor flange cuff (6)
* An alignment mark (5) for installation
6. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* A foam ring (3)
* An alignment tab (2) for installing into the adapter and bearing assembly
* A view of the inside of the connector
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 8. Install the connector to the sensor.
9. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A raised rotor flange cuff (5)
* An alignment mark (4) for installation
10. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 12. Install the connector to the sensor.
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Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel
Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8008
13. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A raised rotor flange cuff (4)
* An alignment mark (3) for installation
14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 16. Install the connector to the sensor.
17. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
* An alignment mark (3) for installation
18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 20. Install the connector to the sensor.
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and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel
Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8009
21. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A flush rotor flange cuff (5)
* An alignment mark (4) for installation
* A foam ring (6)
22. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 24. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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System - Service And Re-Learning Sensor IDs > Page 8015
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
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System - Service And Re-Learning Sensor IDs > Page 8016
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
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5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
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10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
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13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Indicator Sensor Replacement
Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Wheels
and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle.
Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and
Tires/Tires/Service and Repair/Removal and
Replacement).
Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the
inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 Nm (62 lb in).
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Indicator Sensor Replacement > Page 8022
Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting.
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and
Tires/Tires/Service and Repair/Removal and
Replacement).
Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor
unique identification code cannot be learned into the body control module (BCM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensors internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure
sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Wheels and Tires/Tire Monitoring
System/Service and Repair
).
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Indicator Sensor Replacement > Page 8023
Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement
Tire Valve Stem Grommet Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Wheels
and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle.
Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting:
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead
from the wheel.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the outside of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and
Tires/Tires/Service and Repair/Removal and
Replacement).
Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure
Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all
residual liquid sealant from the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the
sensor grommet from the valve stem.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor
valve stem.
3. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Indicator Sensor Replacement > Page 8024
4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 Nm (62 lb in).
Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and
Tires/Tires/Service and Repair/Removal and
Replacement).
6. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Wheels and Tires/Service and Repair). 7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Steering Knuckle Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Support the
lower control arm with a suitable jack.
Note: In the following service procedure, it is NOT necessary to separate the brake caliper and
mounting bracket. Remove them as an assembly. Support the assembly with mechanics wire or
equivalent.
4. Remove the brake caliper assembly and relocate to the side. Refer to Brake Caliper Bracket
Replacement (See: Brakes and Traction Control/Disc
Brake System/Brake Caliper/Service and Repair/Brake Caliper Bracket Replacement).
Note: Perform the following service procedure if the vehicle is equipped with 4WD. If the vehicle
does not have 4WD, proceed to Step 6.
5. Separate the front wheel drive shaft from the steering knuckle. Refer to Wheel Drive Shaft
Replacement (See: Transmission and Drivetrain/Drive
Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair).
6. Remove the speed senor wiring harness from the retaining clips on the upper control arm and
frame. 7. Remove the outer tie rod end from the knuckle. Refer to Steering Linkage Outer Tie Rod
Replacement (See: Tie Rod/Service and Repair/Steering
Linkage Outer Tie Rod Replacement).
8. Separate the upper ball joint from the knuckle. Refer to Upper Control Arm Ball Joint
Replacement (2WD, Z85, ZQ8) (See: Suspension/Ball
Joint/Service and Repair/Front Suspension/Upper Control Arm Ball Joint Replacement)Upper
Control Arm Ball Joint Replacement (4WD, 2WD, Z71) (See: Suspension/Ball Joint/Service and
Repair/Upper Control Arm Ball Joint Replacement).
9. Separate the lower ball joint from the knuckle. Refer to Lower Control Arm Ball Joint
Replacement (4WD, 2WD, Z71) (See: Suspension/Ball
Joint/Service and Repair/Lower Control Arm Ball Joint Replacement)Lower Control Arm Ball Joint
Replacement (2WD, Z85, ZQ8) (See: Suspension/Ball Joint/Service and Repair/Front
Suspension/Lower Control Arm Ball Joint Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 8029
Note: Remove the wheel hub and bearing assembly and knuckle as a unit.
10. Remove the knuckle from the upper and lower control arms. 11. Remove the wheel hub and
bearing assembly from the knuckle. Refer to Front Wheel Bearing and Hub Replacement (See:
Suspension/Wheel
Bearing/Service and Repair).
Installation Procedure
1. Install the wheel hub and bearing assembly onto the knuckle. Refer to Front Wheel Bearing and
Hub Replacement (See: Suspension/Wheel
Bearing/Service and Repair).
2. Install the lower control arm/ball joint into the knuckle. Refer to Lower Control Arm Ball Joint
Replacement (4WD, 2WD, Z71) (See:
Suspension/Ball Joint/Service and Repair/Lower Control Arm Ball Joint Replacement)Lower
Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) (See: Suspension/Ball Joint/Service and
Repair/Front Suspension/Lower Control Arm Ball Joint Replacement).
Note: The following service procedure is for vehicles equipped with 4WD only. If the vehicle is not
equipped with 4WD, proceed to Step 4.
3. Install the wheel drive shaft into the knuckle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 8030
4. Install the upper control arm/ball joint into the knuckle. Refer to Upper Control Arm Ball Joint
Replacement (2WD, Z85, ZQ8) (See:
Suspension/Ball Joint/Service and Repair/Front Suspension/Upper Control Arm Ball Joint
Replacement)Upper Control Arm Ball Joint Replacement (4WD, 2WD, Z71) (See: Suspension/Ball
Joint/Service and Repair/Upper Control Arm Ball Joint Replacement).
5. Install the outer tie rod end into the knuckle. Refer to Steering Linkage Outer Tie Rod
Replacement (See: Tie Rod/Service and Repair/Steering
Linkage Outer Tie Rod Replacement).
6. Install the speed senor wiring harness in the retaining clips on the upper control arm and frame.
7. Install the brake caliper mounting bracket. Refer to Brake Caliper Bracket Replacement (See:
Brakes and Traction Control/Disc Brake
System/Brake Caliper/Service and Repair/Brake Caliper Bracket Replacement).
8. Install the wheel drive shaft retaining nut to specifications. Refer to Wheel Drive Shaft
Replacement (See: Transmission and Drivetrain/Drive
Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair).
9. Remove the support from the lower control arm.
10. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair) 11. Remove the support and lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair
Power Steering Bleeding: Service and Repair
Power Steering System Bleeding
Important: *
Use clean, new power steering fluid type only. See the Maintenance and Lubrication subsection for
fluid specifications. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service
Intervals).
* Hoses touching the frame, body or engine may cause system noise. Verify that the hoses do not
touch any other part of the vehicle.
* Loose connections may not leak, but could allow air into the steering system. Verify that all hose
connections are tight.
Important: Power steering fluid level must be maintained throughout bleed procedure.
1. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash mark
on cap stick fluid level indicator.
Important: With hydro-boost only, the oil level will appear falsely high if the hydro-boost
accumulator is not fully charged. Do not apply the brake pedal with the engine OFF. This will
discharge the hydro-boost accumulator.
2. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following
procedure:
1. Start the engine. 2. Firmly apply the brake pedal 10-15 times. 3. Turn the engine OFF.
3. Raise the vehicle until the front wheels are off the ground. Refer to Lifting and Jacking the
Vehicle (See: Wheels and Tires/Vehicle
Lifting/Service and Repair).
4. Key on engine OFF, turn the steering wheel from stop to stop 12 times.
Vehicles equipped with hydro-boost systems or longer length power steering hoses may require
turns up to 15 to 20 stop to stops.
5. Verify power steering fluid level per operating specification. Refer to Checking and Adding Power
Steering Fluid (See: Service and
Repair/Checking and Adding Power Steering Fluid).
6. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid
aeration (pump noise/whining). 7. Verify the fluid level. Repeat the bleed procedure, if necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid >
Component Information > Specifications
Power Steering Fluid: Specifications
POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N
89021186) or equivalent.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Locations
Power Steering Fluid Reservoir: Locations
Power Steering Pump Disassembled View
1 - Hydraulic Pump Reservoir Assembly (Typical) 2 - Reservoir Capstick Assembly 3 - O-Ring Seal
4 - Flow Control Spring 5 - Control Valve Assembly 6 - O-Ring Seal 7 - O-Ring Union Fitting 8 Hydraulic Pump Housing Assembly 9 - Reservoir Retaining Clip (RH) 10 - Reservoir Retaining Clip
(LH)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Locations > Page 8041
Power Steering Fluid Reservoir: Service and Repair
Power Steering Fluid Reservoir Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service Precautions
Power Steering Line/Hose: Service Precautions
Power Steering Hose Disconnected Caution
Caution: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected.
When disconnected, plug or cap all openings of components. Failure to do so could result in
contamination or loss of power steering fluid and damage to the system.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service Precautions > Page 8045
Power Steering Line/Hose: Service and Repair
Power Steering Gear Inlet and Outlet Hose Replacement (LH8) (5.3L)
Removal Procedure
1. Remove as much power steering fluid from the power steering fluid reservoir as possible. 2.
Remove the engine protection shield. Refer to Engine Protection Shield Replacement (See: Body
and Frame/Frame/Skid Plate/Service and
Repair).
3. Place drain pans under the vehicle as needed.
4. Disconnect the power steering gear inlet and outlet hose (1) from the power steering pump and
power steering fluid reservoir assembly.
5. Remove the power steering gear inlet and outlet hose bracket bolts (2). 6. Remove the power
steering gear inlet and outlet hose retaining plate bolt (1). 7. Disconnect the power steering gear
inlet and outlet hose (3) from the steering gear and remove it from the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service Precautions > Page 8046
8. Clean the power steering gear inlet and outlet hose ports at the steering gear of any debris. 9.
Transfer any parts as needed.
Installation Procedure
1. Install the power steering gear inlet and outlet hose (3) to the vehicle and connect it to the
steering gear.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the power steering gear inlet and outlet hose retaining plate bolt (1) and tighten to 12 Nm
(106 lb in). 3. Install the power steering gear inlet and outlet hose bracket bolts (2) and tighten to 9
Nm (80 lb in).
4. Connect the power steering gear inlet and outlet hose (1) to the power steering pump and power
steering fluid reservoir assembly. Tighten the
fitting to 25 Nm (18 lb ft).
5. Clean any excess power steering fluid from the vehicle and remove the drain pans. 6. Install the
engine protection shield. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid Plate/Service and Repair). 7. Fill and bleed the power steering system. Refer to
Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor >
Component Information > Technical Service Bulletins > Steering - Power Steering Pump Replacement Tips
Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement
Tips
INFORMATION
Bulletin No.: 06-02-32-013B
Date: August 07, 2009
Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is
Necessary
Models:
1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER
H2, H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years and update the information. Please
discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering).
A recently completed analysis of returned power steering (PS) pumps that had been replaced for
noise, no power assist, no or low pressure and leaking conditions has indicated a high number of
"No Trouble Found" results.
Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering
concern, the steering system analyzer should be utilized to assist the technician in a successful
diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer.
In addition, extensive warranty analysis has shown that the following situations are all significant
root causes of PS pump failures:
- Improper pulley installation
- Re-using the O-rings
- Using fluid other than the OE-specified steering fluid
- Failure to flush the PS system
In order to help improve customer satisfaction and reduce comebacks, GM recommends the
following tips for replacing a PS pump:
1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which
could cause the pressure relief valve to stop
functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will
result in pump failure.
2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical,
distorting the pulley may damage bearings on the
new PS pump.
Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts
Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for
the vehicle.
3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must
be lubricated with OE-specific PS fluid prior to
installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT
covering the pressure bypass hole.
4. Bleed the PS system according to the procedures/recommendations in SI.
Following these procedures and using the correct tools and fluids should help ensure that the new
PS pump operates properly. Skipping steps may cost you time and trouble later.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control
Valve > Component Information > Service and Repair
Power Steering Pressure Control Valve: Service and Repair
Power Steering Pump Flow Control Valve Replacement - Off Vehicle
Disassembly Procedure
1. Remove the O-ring union fitting (5) from the hydraulic pump housing assembly (1). 2. Remove
the O-ring seal (4) from the O-ring union fitting (5). 3. Remove the control valve assembly (3). 4.
Remove the flow control spring (2).
Assembly Procedure
1. Install the flow control spring (2) to the hydraulic pump housing assembly (1). 2. Install the
control valve assembly (3). 3. Lubricate the new O-ring seal (4) with power steering fluid. 4. Install
the O-ring seal (4) on to the O-ring union fitting (5).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Install the O-ring union fitting (5) into the hydraulic pump housing assembly (1). Tighten the
O-ring union fitting to 75 Nm (55 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Power
Steering Pump Seal > Component Information > Service and Repair
Power Steering Pump Seal: Service and Repair
Power Steering Pump Shaft Seal Replacement
Removal Procedure
1. Remove the power steering pump from the vehicle, if necessary. Refer to Power Steering Pump
Replacement (LLV, LLR) (See: Service and
Repair)Power Steering Pump Replacement (LH8) (See: Service and Repair).
Important: Protect the drive shaft with the shim stock.
2. Use a small chisel in order to remove the seal.
Discard the seal.
Installation Procedure
1. Lubricate the new drive shaft seal using power steering fluid.
2. Use a deep socket in order to install the new drive shaft seal. 3. Install the power steering pump,
if removed. Refer to Power Steering Pump Replacement (LLV, LLR) (See: Service and
Repair)Power Steering
Pump Replacement (LH8) (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle
Sensor > Component Information > Diagrams
Steering Angle Sensor: Diagrams
Component Connector End Views
Steering Wheel Position Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle
Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing
Replacement
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft
Lower Bearing Replacement
Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle
Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing
Replacement > Page 8064
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering
Steering Wheel Position Sensor Centering
Removal Procedure
Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE
removing the sensor from the steering column. Once you have identified the steering wheel
position sensor, follow the instructions listed in the removal procedure.
1. Verify the type of steering wheel position sensor.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right.
Important: If reusing the existing sensor, you do not have to align the sensor before removal.
Centering is not required when it is time to reinstall.
3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing
assembly. 5. To install the sensor, proceed to step 1 in the installation section.
6. From the technicians point of view, the FRONT of the sensor will have:
* A foam ring (2)
* A pin hole (1) for centering the pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff
(3) before removing the sensor. Failure to do so will cause misalignment when installing the
sensor. A new sensor will be required if misaligned.
7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the
sensor. 9. Remove the sensor from the adapter and bearing assembly.
10. To install the sensor, proceed to step 5 in the installation procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle
Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing
Replacement > Page 8065
11. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note the location of the pin hole.
12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing
assembly. 14. To install the sensor, proceed to step 9 in the installation procedure.
15. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note location of the pin hole.
* A sensor clip in FRONT of the sensor
16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18.
Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to
step 13 in the installation procedure.
20. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (3)
* A pin hole (1) for the centering pin-Note the location of the pin hole.
* An alignment mark (2) on the flush rotor flange cuff (3) for installation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle
Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing
Replacement > Page 8066
21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing
assembly. 23. To install the sensor, proceed to step 17 in the installation procedure.
24. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (4)
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* An alignment mark (3) on the flush rotor flange cuff (4) for installation
* A foam ring (1)
25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing
assembly. 27. To install the sensor, proceed to step 21 in the installation procedure.
Installation Procedure
Important: If reusing the existing sensor, no centering of the sensor is required.
1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin
until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1)
connector will be on your right.
From the technicians point of view, the BACK of the sensor (2) connector will be on your left.
3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 4. Install the connector to the sensor.
5. From the technicians point of view, the FRONT of the sensor will have:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle
Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing
Replacement > Page 8067
* A foam ring (4)
* A pin hole (7) for the centering pin-Note the location of the pin hole.
* A flushed rotor flange cuff (6)
* An alignment mark (5) for installation
6. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* A foam ring (3)
* An alignment tab (2) for installing into the adapter and bearing assembly
* A view of the inside of the connector
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 8. Install the connector to the sensor.
9. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A raised rotor flange cuff (5)
* An alignment mark (4) for installation
10. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 12. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle
Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing
Replacement > Page 8068
13. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A raised rotor flange cuff (4)
* An alignment mark (3) for installation
14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 16. Install the connector to the sensor.
17. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
* An alignment mark (3) for installation
18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 20. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle
Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing
Replacement > Page 8069
21. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A flush rotor flange cuff (5)
* An alignment mark (4) for installation
* A foam ring (6)
22. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 24. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Diagrams
Steering Angle Sensor: Diagrams
Component Connector End Views
Steering Wheel Position Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft
Lower Bearing Replacement
Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8075
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering
Steering Wheel Position Sensor Centering
Removal Procedure
Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE
removing the sensor from the steering column. Once you have identified the steering wheel
position sensor, follow the instructions listed in the removal procedure.
1. Verify the type of steering wheel position sensor.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right.
Important: If reusing the existing sensor, you do not have to align the sensor before removal.
Centering is not required when it is time to reinstall.
3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing
assembly. 5. To install the sensor, proceed to step 1 in the installation section.
6. From the technicians point of view, the FRONT of the sensor will have:
* A foam ring (2)
* A pin hole (1) for centering the pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff
(3) before removing the sensor. Failure to do so will cause misalignment when installing the
sensor. A new sensor will be required if misaligned.
7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the
sensor. 9. Remove the sensor from the adapter and bearing assembly.
10. To install the sensor, proceed to step 5 in the installation procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8076
11. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note the location of the pin hole.
12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing
assembly. 14. To install the sensor, proceed to step 9 in the installation procedure.
15. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note location of the pin hole.
* A sensor clip in FRONT of the sensor
16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18.
Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to
step 13 in the installation procedure.
20. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (3)
* A pin hole (1) for the centering pin-Note the location of the pin hole.
* An alignment mark (2) on the flush rotor flange cuff (3) for installation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8077
21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing
assembly. 23. To install the sensor, proceed to step 17 in the installation procedure.
24. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (4)
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* An alignment mark (3) on the flush rotor flange cuff (4) for installation
* A foam ring (1)
25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing
assembly. 27. To install the sensor, proceed to step 21 in the installation procedure.
Installation Procedure
Important: If reusing the existing sensor, no centering of the sensor is required.
1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin
until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1)
connector will be on your right.
From the technicians point of view, the BACK of the sensor (2) connector will be on your left.
3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 4. Install the connector to the sensor.
5. From the technicians point of view, the FRONT of the sensor will have:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8078
* A foam ring (4)
* A pin hole (7) for the centering pin-Note the location of the pin hole.
* A flushed rotor flange cuff (6)
* An alignment mark (5) for installation
6. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* A foam ring (3)
* An alignment tab (2) for installing into the adapter and bearing assembly
* A view of the inside of the connector
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 8. Install the connector to the sensor.
9. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A raised rotor flange cuff (5)
* An alignment mark (4) for installation
10. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 12. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8079
13. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A raised rotor flange cuff (4)
* An alignment mark (3) for installation
14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 16. Install the connector to the sensor.
17. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
* An alignment mark (3) for installation
18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 20. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8080
21. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A flush rotor flange cuff (5)
* An alignment mark (4) for installation
* A foam ring (6)
22. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 24. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming
> System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations).
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Warning
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR
deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power
to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG
warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See:
Diagrams/Electrical Diagrams/Air Bag Systems) or
Electrical Center Identification Views (See: Maintenance/Fuses and Circuit
Breakers/Fuse/Application and ID).
4. Wait 1 minute before working on the system.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming
> System Information > Service and Repair > Page 8085
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to
SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical
Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and
ID).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to
Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
4. Wait 1 minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer
to Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Diagrams
Steering Gear: Diagrams
Power Steering Gear Disassembled View
Rack and Pinion Power Steering Gear
1 - Hexagon Torque Prevailing Nut 2 - Tie Rod Seal 3 - Outer Tie Road Assembly 4 - Hexagon
Jam Nut 5 - Tie Rod End Clamp 6 - Rack and Pinion Boot 7 - Boot Clamp 8 - Inner Tie Rod
Assembly 9 - Shock Dampener Ring 10 - Adjuster Plug Lock Nut 11 - Cylinder Line Assembly (RH)
12 - Cylinder Line Assembly (LH) 13 - O-Ring Seal 14 - O-Ring Seal 15 - Rack and Pinion Gear
Assembly (Partial) 16 - Needle Bearing Annulus Assembly 17 - Seal Adapter 18 - Retaining Ring
19 - Spool Shaft Seal 20 - Hexagon Lock Nut 21 - Dust Cover 22 - Shock Dampener Ring 23 Inner Tie Rod Assembly 24 - Breather Tube 25 - Boot Clamp 26 - Rack and Pinion Boot 27 - Tie
Rod End Clamp 28 - Hexagon Jam Nut 29 - Outer Tie Rod Assembly 30 - Tie Rod Seal 31 Hexagon Torque Prevailing Nut
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle
Steering Gear: Service and Repair Steering Gear Boot and Breather Tube Replacement - Off
Vehicle
Steering Gear Boot and Breather Tube Replacement - Off Vehicle
Tools Required
J 22610 Keystone Clamp Pliers.
Disassembly Procedure
1. To remove the outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie
Rod/Service and Repair/Steering Linkage Outer Tie
Rod Replacement).
2. Remove the hexagon jam nut (2) from the inner tie rod assembly (1).
3. Remove the tie rod end clamp (2) from the rack and pinion boot (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8091
4. Remove the boot clamp (1) from the rack and pinion boot with side cutters. 5. Discard the boot
clamp (1).
Important: *
If a breather tube is present, mark the location of the breather tube on the gear assembly before
removal of the rack and pinion boot.
* After removing the boot, inspect the inner tie rod for evidence of corrosion or contamination. If
none is evident, continue with the repair. If corrosion or contamination is evident, replace the
steering gear.
6. Remove the rack and pinion boot (1) and the breather tube, if present, from the rack and pinion
gear assembly.
Assembly Procedure
1. Install the new boot clamp (1) onto the rack and pinion boot (3).
2. Prior to rack and pinion boot installation, apply grease to the inner tie rod assembly (2) and the
rack and pinion gear assembly (1). 3. Install the rack and pinion boot (3) onto the inner tie rod
assembly (2). 4. If present, install the breather tube while aligning the breather tube with the mark
made during removal and the molded nipple of the rack and
pinion boot.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8092
Important: The rack and pinion boot (3) must not be twisted, puckered or out of shape in any way. If
the rack and pinion boot (3) is not shaped properly, adjust the rack and pinion boot (3) by hand
before installing the boot clamp.
5. Install the rack and pinion boot onto the gear assembly (1) until the rack and pinion boot (3) is
seated in the gear assembly groove.
6. Install the boot clamp (1) on the rack and pinion boot (2) with J 22610 . 7. Crimp the boot clamp
(1). 8. Pinch the pliers together on the rack and pinion boot (2) in order to install the tie rod end
clamp.
9. Install the tie rod end clamp (2) onto the rack and pinion boot (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8093
10. Install the hexagon jam nut (2) to the inner tie rod assembly (1). 11. To assemble the outer tie
rod assembly. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and
Repair/Steering
Linkage Outer Tie Rod Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8094
Steering Gear: Service and Repair Steering Gear Cylinder Pipe Assembly and Seals Replacement
- Off Vehicle
Steering Gear Cylinder Pipe Assembly and Seals Replacement - Off Vehicle
Disassembly Procedure
1. Loosen both cylinder line fittings on the cylinder end of the gear assembly. 2. Loosen both
fittings on the cylinder line assemblies (1) at the valve end of the gear assembly. 3. Remove both
cylinder line assemblies (1) from the rack and pinion gear assembly (2).
4. Remove the O-ring seals (1) from the valve end of line. 5. Discard the O-ring seals (1).
Assembly Procedure
1. Inspect the cylinder lines (1) for the following items:
* Cracks
* Dents
* Damage to the threads
2. Replace the parts as needed.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8095
3. Install the new O-ring seals (1) to the valve end of the cylinder lines.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the cylinder line assemblies (1) to the gear assembly (2).
* Tighten the valve end fittings to 15 Nm (11 lb ft).
* Tighten the cylinder end fittings to 15 Nm (11 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8096
Steering Gear: Service and Repair Steering Gear Rack Bearing Preload Adjustment - Off Vehicle
Steering Gear Rack Bearing Preload Adjustment - Off Vehicle
Special Tools
J 45059 Angle Meter
1. Loosen the adjuster plug lock nut (1).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Tighten the adjuster plug.
For vehicles with allen head adjuster plug:
* Tighten the adjuster plug to 15 Nm (11 lb ft).
* Use J 45059 to back off the adjuster plug 25 degrees.
For vehicles with hex head adjuster plug:
* Tighten the adjuster plug to 12 Nm (106 lb in).
* Use J 45059 to back off the adjuster plug 105 degrees.
3. Tighten the adjuster plug lock nut (1) to the steering gear housing.
Hold the adjuster plug stationary while tightening the adjuster plug lock nut (1) to 60 Nm (44 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8097
Steering Gear: Service and Repair Steering Gear Replacement
Steering Gear Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Remove both of the front tire and wheel assemblies.
Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and
Repair).
3. Remove the engine protection shield if equipped. Refer to Engine Protection Shield
Replacement (See: Body and Frame/Frame/Skid
Plate/Service and Repair).
4. Disconnect the outer tie rod end from the steering knuckle. Refer to Steering Linkage Outer Tie
Rod Replacement (See: Tie Rod/Service and
Repair/Steering Linkage Outer Tie Rod Replacement).
5. Place a drain pan to catch the fluid.
6. Disconnect the power steering hose assembly from the steering gear. Refer to Power Steering
Gear Inlet and Outlet Hose Replacement (LLV,
LLR) (See: Power Steering/Power Steering Line/Hose/Service and Repair)Power Steering Gear
Inlet and Outlet Hose Replacement (LH8) (See: Power Steering/Power Steering Line/Hose/Service
and Repair).
7. Remove the coupler clamp bolt from the intermediate shaft. Refer to Lower Intermediate
Steering Shaft Replacement (See: Steering
Column/Service and Repair/Lower Intermediate Steering Shaft Replacement).
8. Separate the intermediate shaft from the steering gear.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8098
9. Remove the steering gear vertical mounting nuts, the washers and the bolts.
10. Remove the steering gear horizontal mounting nuts, the washers and the bolts. 11. Remove the
crossmember, 2WD ONLY. Refer to Crossmember Replacement (See:
Suspension/Cross-Member/Service and Repair/Crossmember
Replacement).
12. Remove the steering gear from the vehicle.
Installation Procedure
1. Install the steering gear into the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8099
2. Loose install the steering gear horizontal mounting nuts, the washers and the bolts. 3. Install the
crossmember, 2WD ONLY. Refer to Crossmember Replacement (See:
Suspension/Cross-Member/Service and Repair/Crossmember
Replacement).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Loose install the steering gear vertical mounting nuts, the washers and the bolts.
* Tighten the long bolts to 130 Nm (96 lb ft).
* Tighten the isolator clamp bolts to 100 Nm (74 lb ft).
5. Install the intermediate shaft to the steering gear. 6. Install the coupler clamp bolt to the
intermediate shaft. Refer to Lower Intermediate Steering Shaft Replacement (See: Steering
Column/Service
and Repair/Lower Intermediate Steering Shaft Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8100
7. Connect the power steering hose assembly to the steering gear. Refer to Power Steering Gear
Inlet and Outlet Hose Replacement (LLV, LLR) (
See: Power Steering/Power Steering Line/Hose/Service and Repair)Power Steering Gear Inlet and
Outlet Hose Replacement (LH8) (See: Power Steering/Power Steering Line/Hose/Service and
Repair).
8. Install the engine protection shield, if equipped. Refer to Engine Protection Shield Replacement
(See: Body and Frame/Frame/Skid Plate/Service
and Repair).
9. Install the outer tie rod end to the steering knuckle. Refer to Steering Linkage Outer Tie Rod
Replacement (See: Tie Rod/Service and
Repair/Steering Linkage Outer Tie Rod Replacement).
10. Install both of the front tire and wheel assemblies. Refer to Tire and Wheel Removal and
Installation (See: Wheels and Tires/Service and Repair). 11. Lower the vehicle. 12. Bleed the
power steering system. Refer to Power Steering System Bleeding (See: Power Steering/Power
Steering Bleeding/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service
and Repair > Steering Shaft Upper Bearing Replacement
Steering Shaft: Service and Repair Steering Shaft Upper Bearing Replacement
Steering Shaft Upper Bearing Replacement
Removal Procedure
1. Remove the steering column tilt head housing. Refer to Steering Column Tilt Head Housing
Replacement (See: Steering Column/Service and
Repair/Steering Column Tilt Head Housing Replacement).
2. Remove the steering shaft upper bearing from the steering column tilt head housing.
Installation Procedure
1. Install the steering shaft upper bearing into the steering column tilt head housing. 2. Install the
steering column tilt head housing. Refer to Steering Column Tilt Head Housing Replacement (See:
Steering Column/Service and
Repair/Steering Column Tilt Head Housing Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service
and Repair > Steering Shaft Upper Bearing Replacement > Page 8105
Steering Shaft: Service and Repair Steering Shaft Replacement (Tilt Column)
Steering Shaft Replacement (Tilt Column)
Removal Procedure
1. Remove the steering column tilt head housing. Refer to Steering Column Tilt Head Housing
Replacement (See: Steering Column/Service and
Repair/Steering Column Tilt Head Housing Replacement).
2. Remove the steering column shaft.
Installation Procedure
1. Install the steering column shaft. 2. Install the steering column tilt head housing. Refer to
Steering Column Tilt Head Housing Replacement (See: Steering Column/Service and
Repair/Steering Column Tilt Head Housing Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Description and Operation
Steering Wheel: Description and Operation
Steering Wheel and Column Description and Operation
The steering wheel and column has 4 primary functions:
* Vehicle steering
* Vehicle security
* Driver convenience
* Driver safety
Vehicle Steering
The steering wheel is the first link between the driver and the vehicle. The steering wheel is
fastened to a steering shaft within the column. At the lower end of the column, the intermediate
shaft connects the column to the steering gear.
Vehicle Security, Found on Some Vehicle Models
Theft deterrent components are mounted and designed into the steering column. The following
components allow the column to be locked in order to minimize theft:
* The ignition switch-location varies
* The steering column lock-content varies
* The ignition cylinder-location varies
* The theft deterrent module-location varies
Driver Convenience
The steering wheel and column may also have driver controls attached for convenience and
comfort. The following controls may be mounted on or near the steering wheel or column.
* The turn signal switch
* The hazard switch
* The headlamp dimmer switch
* The wiper/washer switch
* The horn pad/cruise control switch
* The redundant radio/entertainment system controls
* The manual/power tilt or tilt/telescoping functions
* The power pedal adjustment control switch
* The navigation/OnStar(R) features
* The HVAC controls
Driver Safety
The steering wheel and column has safety features to protect the driver. The following components
may be mounted on or near the steering column: Energy-Absorbing Steering Column
- The energy-absorbing steering column compresses in the event of a front-end collision, which
reduces the chance of injury to the driver. The energy-absorbing feature, collapsible steering shaft,
and break away mounting features help reduce the injury in the event of an accident. In addition to
these features, the following driver safety features may be on the steering column. To inspect the
steering column for damage, refer to Steering Column Accident Damage Inspection (See: Steering
Column/Testing and Inspection/Initial Inspection and Diagnostic Overview/Steering Column
Accident Damage Inspection).
Electronic Park Lock (EPL)/Ignition Lock Cylinder Control Actuator
- If the vehicle is equipped with automatic transmission and a floor mounted console gear shift, it
has an ignition lock cylinder control actuator system in the steering column. The ignition lock
cylinder control actuator purpose is to prevent the ignition key from being turned to the OFF
position when the transmission is in any position other than PARK and the vehicle may still be
moving. The column ignition lock system consists of an ignition lock cylinder control actuator, and a
park position switch that is located in the automatic transmission shift lock control switch. The
ignition lock cylinder control actuator contains a pin that is spring loaded to mechanically prevent
the ignition key cylinder from being turned to the lock position when the vehicle transmission is not
in the PARK position. If vehicle power is lost, and/or the transmission is not in the PARK position
the operator will not be able to turn the ignition key to the lock position and will not be able to
remove the ignition key from the column.
Linear Shift Assembly
- If the vehicle is equipped with a column mounted gear shift, it has a linear shift assembly on the
steering column. The linear shift assembly has a cable that runs from the linear shift assembly to
the ignition lock cylinder case. The purpose of this cable is to prevent the ignition key from being
turned to the OFF position when the transmission is in gear and the vehicle may still be moving.
The linear shift assembly cable contains a pin that
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Description and Operation > Page 8109
is spring loaded to mechanically prevent the ignition key cylinder from being turned to the lock
position when the vehicle transmission is not in the PARK position. If vehicle power is lost, and/or
the transmission is not in the PARK position the operator will not be able to turn the ignition key to
the lock position and will not be able to remove the ignition key from the column.
SIR Coil and Module
- For additional information on the operation of the SIR coil and module, refer to SIR System
Description and Operation (See: Restraint Systems/Air Bag Systems/Description and Operation).
Automatic Transmission Shift Lock Actuator
- The automatic transmission shift lock control system is a safety device that prevents an
inadvertent shift out of PARK when the engine is running. The driver must press the brake pedal
before moving the shift lever out of the PARK position. The system consists of the following
components: the automatic transmission shift lock control solenoid, the automatic transmission shift
lock control switch, the body control module (BCM), the powertrain control module (PCM)/engine
control module (ECM). With the ignition in the ON position, voltage is supplied to automatic
transmission shift lock control switch. Voltage flows through the normally closed contacts of the
automatic transmission shift lock control switch to the automatic transmission shift lock control
solenoid. When the BCM receives a class 2 message from the PCM/ECM indicating the
transmission is in the park position the BCM then grounds the automatic transmission shift lock
solenoid control circuit. This energizes the automatic transmission shift lock control solenoid
causing the transmission shift lever to be physically locked in the PARK position. When the brake
pedal is pressed the contacts in the automatic transmission shift lock control switch open,
de-energizing the automatic transmission shift lock control solenoid. This allows the shift lever to be
move out of the PARK position.
Steering Wheel Angle Sensor or Steering Wheel Position Sensor
- The steering wheel position sensor is located somewhere along the steering shaft assembly. The
sensor measures the position of the steering wheel and the speed at which it is rotated. A signal
representing this measurement is provided to the vehicle stability enhancement system (VSES)
module. The VSES module uses this signal, along with several others representing different vehicle
conditions, to monitor the driving behavior of the vehicle and ensure that it stays in control. If the
VSES module determines that the vehicle is out of control it provides signals to the powertrain
control module (PCM) and the ABS module. These output signals are used to modulate the
transmission torque and brake pressure of each of the vehicles wheels in order to regain control of
the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Description and Operation > Page 8110
Steering Wheel: Service and Repair
Steering Wheel Replacement
Special Tools
J 42640 Steering Column Anti-Rotation Pin
Removal Procedure
1. Set the front wheels in the straight-ahead position. 2. Lock the steering column through the
access hole in the lower steering column trim cover using anti-rotation pin J 42640 . 3. Remove the
inflatable restraint steering wheel module. Refer to Steering Wheel Inflatable Restraint Module
Replacement (See: Restraint
Systems/Air Bag Systems/Air Bag/Service and Repair).
4. Make alignment marks in order to note the relationship between the steering wheel and the
steering shaft.
5. Loosen the steering wheel nut 2 complete rotations. 6. Carefully pull on the steering wheel until it
comes loose from the steering column. 7. Remove the steering wheel nut (2). 8. Remove the
steering wheel from the steering column using caution to guide the electrical connectors (1,3)
through it without damaging them.
Installation Procedure
Caution: Improper alignment of the steering wheel to the steering column shaft will cause vehicle
damage. In order to prevent vehicle damage, ensure that the steering wheel is properly indexed to
the steering column before tightening the steering wheel nut.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Description and Operation > Page 8111
1. If installing a new steering wheel perform the following:
1. Ensure the front wheels are still set in the straight-ahead position. 2. Position the steering wheel
near the steering shaft with the arrow (1) at the 12 o'clock position. 3. Ensure that proper tooth
alignment between the steering wheel and the steering shaft has been achieved (2).
2. If installing the original steering wheel perform the following:
1. Position the steering wheel to the steering column. 2. Align the marks made during the removal
of the steering wheel.
3. Ensure the electrical connectors (1,3) are not pinched between the steering column and the
steering wheel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the steering wheel nut (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Description and Operation > Page 8112
Tighten the nut to 35 Nm (26 lb ft).
5. Install the inflatable restraint steering wheel module. Refer to Steering Wheel Inflatable Restraint
Module Replacement (See: Restraint
Systems/Air Bag Systems/Air Bag/Service and Repair).
6. Remove anti-rotation pin J 42640 .
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and
Inspection > Steering Linkage Inner Tie Rod Inspection
Tie Rod: Testing and Inspection Steering Linkage Inner Tie Rod Inspection
Steering Linkage Inner Tie Rod Inspection
Special Tools
J 8001 Dial Indicator Set
1. Turn the ignition key to the on position with the engine off. 2. With the aid of an assistant, turn
the steering wheel to the full stop position and hold it in that position until the test is complete. The
tie rod being
tested should be inside the steering gear housing seated against the steering stop.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair).
4. If there is not a good location for the dial indicator pointer at the steering gear housing, install a
large worm gear hose clamp to the steering gear
housing over the larger steering gear boot clamp and align the clamp so that the screw can be a
location for the dial indicator pointer.
5. Install a dial indicator between the inner tie rod (2) and the steering gear housing or the worm
gear clamp in such a way as to measure the lash
between the inner tie rod and the steering gear housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and
Inspection > Steering Linkage Inner Tie Rod Inspection > Page 8117
Important: Only move the tire enough to feel any lash between the inner tie rod and the inner tie
rod housing without moving the steering gear rack.
6. Grasping the tire at the 3 o'clock and 9 o'clock positions, gently push in on one side of the tire to
remove any lash. 7. Zero the dial indicator. 8. On the same side of the tire previously pushed
inwards, gently pull outwards and measure the lash. 9. Record the measurement seen on the dial
indicator.
10. If the measured value exceeds 0.5 mm (0.02 in) then replace the inner tie rod. Refer to
Steering Linkage Inner Tie Rod Replacement - Off Vehicle
(Magnasteer) (See: Service and Repair/Steering Linkage Inner Tie Rod Replacement - Off Vehicle
(Magnasteer))Steering Linkage Inner Tie Rod Replacement - Off Vehicle (Quiet Valve) (See:
Service and Repair/Steering Linkage Inner Tie Rod Replacement - Off Vehicle (Quiet Valve)).
11. Repeat the procedure for the other side.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and
Inspection > Steering Linkage Inner Tie Rod Inspection > Page 8118
Tie Rod: Testing and Inspection Steering Linkage Outer Tie Rod Inspection
Steering Linkage Outer Tie Rod Inspection
Special Tools
J 8001 Dial Indicator Set
1. Inspect the outer tie rod end seal. If the outer tie rod end seal is torn, replace the outer tie rod
end. Refer to Steering Linkage Outer Tie Rod
Replacement (See: Service and Repair/Steering Linkage Outer Tie Rod Replacement).
2. Raise the side of the vehicle being inspected with a floor jack while maintaining contact between
the opposite wheel and the shop floor. Support
the lower control arm with a floor jack stand as far outboard as possible and remove the floor jack.
Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and
Repair).
3. Install dial indicator J 8001 or equivalent between the outer tie rod end and the steering knuckle
as shown in the graphic. Note that the tire and
wheel assembly is shown removed only for clarification of the dial indicator position.
4. Grasping the tire at the 3 o'clock and 9 o'clock positions, gently push in on one side of the tire to
remove any lash. 5. Zero the dial indicator. 6. On the same side of the tire previously pushed
inwards, gently pull outwards and measure the lash. 7. Record the measurement seen on the dial
indicator. 8. Movement should not exceed 0.5 mm (0.02 in). If the movement exceeds 0.5 mm
(0.02 in) then replace the outer tie rod. Refer to Steering Linkage
Outer Tie Rod Replacement (See: Service and Repair/Steering Linkage Outer Tie Rod
Replacement).
9. Repeat this procedure for the other side of the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and
Repair > Steering Linkage Outer Tie Rod Replacement
Tie Rod: Service and Repair Steering Linkage Outer Tie Rod Replacement
Steering Linkage Outer Tie Rod Replacement
Special Tools
J 24319-B Steering Linkage and Tie Rod Puller
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel
Removal and Installation (See: Wheels and Tires/Service and Repair).
3. Remove the outer tie rod retaining nut. Discard the nut.
Caution: Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint
and the attached part. Seal damage may result which will cause premature failure of the joint.
4. Disconnect the outer tie rod from the steering knuckle using J 24319-B . 5. Loosen the jam nut
and remove the outer tie rod from the inner tie rod. Discard the jam nut. 6. Clean the tapered
surface of the steering knuckle.
Installation Procedure
1. Lubricate the inner tie rod threads with a suitable chassis lubricant before installing the outer tie
rod. 2. Install the NEW jam nut to the outer tie rod. 3. Install the outer tie rod to the inner tie rod.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and
Repair > Steering Linkage Outer Tie Rod Replacement > Page 8121
4. Install the outer tie rod to the steering knuckle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Install the NEW outer tie rod retaining nut.
* Tighten the outer tie rod retaining nut to 45 Nm (33 lb ft) plus 95 degrees.
* Tighten the outer tie rod end jam nut to 70 Nm (52 lb ft).
6. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair). 7. Lower the vehicle. 8. Adjust the front toe. Refer to Wheel Alignment Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel
Alignment - Steering Wheel Angle and/or Front Toe Adjustment).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and
Repair > Steering Linkage Outer Tie Rod Replacement > Page 8122
Tie Rod: Service and Repair Steering Linkage Inner Tie Rod Replacement - Off Vehicle
(Magnasteer)
Steering Linkage Inner Tie Rod Replacement - Off Vehicle (Magnasteer)
Special Tools
J 34028 Inner Tie Rod Wrench
Disassembly Procedure
Note: After removing the boot, inspect the inner tie rod for evidence of corrosion or contamination.
If none is evident, continue with the repair. If corrosion or contamination is evident, replace the
steering gear.
1. To remove the rack and pinion boot, refer to Steering Gear Boot and Breather Tube
Replacement - Off Vehicle (See: Steering Gear/Service and
Repair).
2. Place the gear in a vise.
Caution: Do not change the steering gear preload adjustment before moving the inner tie rod from
the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod
could result in damage to the pinion and the steering gear.
3. Remove the shock dampener (6) from the inner tie rod housing (4). 4. Slide the shock dampener
(6) back on the rack (5).
Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage
Warnings/Pipe Wrench Positioning Caution).
5. Place a pipe wrench on the rack (5) next to the inner tie rod housing (4). 6. Place a wrench on
the flats of the inner tie rod housing (4). 7. Rotate the inner tie rod housing (4) counterclockwise,
while holding the rack stationary, until the inner tie rod separates from the rack (5).
8. Remove the shock dampener (3) from the inner tie rod housing (2). 9. Slide the shock dampener
(3) back on the rack (5).
Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage
Warnings/Pipe Wrench Positioning Caution).
10. Place a pipe wrench on the rack. 11. Place a wrench on the flats of the inner tie rod housing
(2). 12. Rotate the inner tie rod housing (2) counterclockwise, while holding the rack stationary,
until the inner tie rod (1) separates from the rack (5).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and
Repair > Steering Linkage Outer Tie Rod Replacement > Page 8123
13. If female rack (1) and male inner tie rod (3), remove the old LOCTITE(R) from the threads (2) of
the inner tie rod (3) and the rack (1).
If male rack (5) and female inner tie rod (4) LOCTITE(R) will not be present.
Assembly Procedure
1. Slide the shock dampener (4) forward onto the rack (3).
Note: Threads must be clean prior to LOCTITE(R) application. Check LOCTITE(R), or equivalent,
container for expiration date. Use only enough LOCTITE(R) to evenly coat threads.
If male rack (3) and female inner tie rod (2) do not apply LOCTITE(R).
2. If female rack (3) and male inner tie rod (2), apply LOCTITE(R) 262, or equivalent, to the inner
tie rod threads. 3. Attach the inner tie rod onto the rack (3).
Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage
Warnings/Pipe Wrench Positioning Caution).
4. Place a pipe wrench on the rack (3) next to the inner tie rod housing (2).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (2). Tighten the inner
tie rod to 100 Nm (74 lb ft).
6. Slide the shock dampener (2) forward onto the rack.
Note: Threads must be clean prior to LOCTITE(R) application. Check LOCTITE(R), or equivalent,
container for expiration date. Use only enough LOCTITE(R) to evenly coat threads.
If male rack and female inner tie rod (1) do not apply LOCTITE(R).
7. If female rack and male inner tie rod (1), apply LOCTITE(R) 262, or equivalent, to the inner tie
rod threads. 8. Attach the inner tie rod (1) onto the rack.
Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage
Warnings/Pipe Wrench Positioning Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and
Repair > Steering Linkage Outer Tie Rod Replacement > Page 8124
9. Place a pipe wrench on the rack next to the inner tie rod housing (4).
10. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (7). Tighten the
inner tie rod to 100 Nm (74 lb ft).
11. Place the inner tie rod assembly (2) in a vise.
Note: If female rack (1) and male inner tie rod (2) do not stake. If male rack (1) and female inner tie
rod (2) you must stake.
12. Stake both sides of the female inner tie rod assembly housing to the male rack (1).
13. Insert a 0.25 mm gage (1) between the rack (2) and the inner tie rod housing in order to check
both stakes. The feeler gage (1) must not pass
between the rack and the housing stake.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and
Repair > Steering Linkage Outer Tie Rod Replacement > Page 8125
14. Slide the shock dampener (2) over the inner tie rod housing (3) until the front lip of the shock
dampener (2) bottoms against the inner tie rod
housing (3).
15. To assemble the rack and pinion boot. Refer to Steering Gear Boot and Breather Tube
Replacement - Off Vehicle (See: Steering Gear/Service
and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and
Repair > Steering Linkage Outer Tie Rod Replacement > Page 8126
Tie Rod: Service and Repair Steering Linkage Inner Tie Rod Replacement - Off Vehicle (Quiet
Valve)
Steering Linkage Inner Tie Rod Replacement - Off Vehicle (Quiet Valve)
Disassembly Procedure
Note: After removing the boot, inspect the inner tie rod for evidence of corrosion or contamination.
If none is evident, continue with the repair. If corrosion or contamination is evident, replace the
steering gear.
1. Remove the rack and pinion boot. Refer to Steering Gear Boot and Breather Tube Replacement
- Off Vehicle (See: Steering Gear/Service and
Repair).
2. Place the gear in a vise.
Caution: Do not change the steering gear preload adjustment before moving the inner tie rod from
the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod
could result in damage to the pinion and the steering gear.
3. Remove the shock dampener (4) from the inner tie rod assembly (6). 4. Slide the shock
dampener (4) back on the rack (5).
Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage
Warnings/Pipe Wrench Positioning Caution).
5. Place a pipe wrench on the rack (5) next to the inner tie rod housing (6). 6. Place a wrench on
the flats of the inner tie rod housing (6). 7. Rotate the inner tie rod housing (6) counterclockwise,
while holding the rack stationary, until the inner tie rod separates from the rack (5).
Caution: Do not change the steering gear preload adjustment before moving the inner tie rod from
the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod
could result in damage to the pinion and the steering gear.
8. Remove the shock dampener (3) from the inner tie rod housing (2). 9. Slide the shock dampener
(3) back on the rack (5).
Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage
Warnings/Pipe Wrench Positioning Caution).
10. Place a pipe wrench on the rack. 11. Place a wrench on the flats of the inner tie rod housing
(2). 12. Rotate the inner tie rod housing (2) counterclockwise, while holding the rack stationary,
until the inner tie rod (1) separates from the rack (5).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and
Repair > Steering Linkage Outer Tie Rod Replacement > Page 8127
13. If female rack (1) and male inner tie rod (3), remove the old LOCTITE(R) from the threads (2) of
the inner tie rod and the rack.
If male rack (5) and female inner tie rod (4) LOCTITE(R) will not be present.
Assembly Procedure
1. Slide the shock dampener (4) forward onto the rack (3).
Note: Threads must be clean prior to LOCTITE(R) application. Check LOCTITE(R) or equivalent
container for expiration date. Use only enough LOCTITE(R) to evenly coat threads.
If male rack (3) and female inner tie rod (2) do not apply LOCTITE(R).
2. If female rack (3) and male inner tie rod (2), apply LOCTITE(R) 262 or equivalent to the inner tie
rod threads. 3. Attach the inner tie rod onto the rack (3).
Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage
Warnings/Pipe Wrench Positioning Caution).
4. Place a pipe wrench on the rack (3) next to the inner tie rod housing (2).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (2). Tighten the inner
tie rod to 100 Nm (74 lb ft).
6. Slide the shock dampener (2) forward onto the rack.
Note: Threads must be clean prior to LOCTITE(R) application. Check LOCTITE(R) or equivalent
container for expiration date. Use only enough LOCTITE(R) to evenly coat threads.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and
Repair > Steering Linkage Outer Tie Rod Replacement > Page 8128
If male rack and female inner tie rod (1) do not apply LOCTITE(R).
7. If female rack and male inner tie rod (1), apply LOCTITE(R) 262 or equivalent to the inner tie rod
threads. 8. Attach the inner tie rod (1) onto the rack.
Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage
Warnings/Pipe Wrench Positioning Caution).
9. Place a pipe wrench on the rack next to the inner tie rod housing (4).
10. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (7). Tighten the
inner tie rod to 100 Nm (74 lb ft).
11. Place the inner tie rod assembly (2) in a vise.
Note: If female rack (1) and male inner tie rod (2) do not stake. If male rack (1) and female inner tie
rod (2) you must stake.
12. Stake both sides of the female inner tie rod assembly housing to the male rack.
13. Insert a 0.25 mm gage (1) between the rack (2) and the inner tie rod housing in order to check
both stakes. The feeler gage (1) must not pass
between the rack and the housing stake.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and
Repair > Steering Linkage Outer Tie Rod Replacement > Page 8129
14. Slide the shock dampener (2) over the inner tie rod housing (3) until the front lip of the shock
dampener (2) bottoms against the inner tie rod
housing (3).
15. To assemble the rack and pinion boot. Refer to Steering Gear Boot and Breather Tube
Replacement - Off Vehicle (See: Steering Gear/Service
and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information >
Specifications
Ball Joint: Specifications
Upper Ball Joint
Maximum Allowable Ball Joint Movement
............................................................................................................................................. 0.50 mm
(0.020 in)
Lower Ball Joint Maximum Allowable Ball Joint Movement
............................................................................................................................................. 0.50 mm
(0.020 in)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing
and Inspection > Ball Joint Inspection (Lower Ball Joint)
Ball Joint: Testing and Inspection Ball Joint Inspection (Lower Ball Joint)
Ball Joint Inspection (Lower Ball Joint)
Special Tools
J 8001 - Dial Indicator Set
Note: *
The vehicle must rest on a level surface.
* The vehicle must be stable. Do not rock the vehicle on the floor stands.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Clean and inspect the ball joint seals for cuts or tears.
If the ball joint seals are damaged, replace the ball joint. Refer to Lower Control Arm Ball
Joint Replacement (4WD, 2WD, Z71) (See: Service and Repair/Lower Control Arm Ball Joint
Replacement)Lower Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) (See: Service and
Repair/Front Suspension/Lower Control Arm Ball Joint Replacement).
3. Support the lower control arm with a floor stand as far outboard as possible and raise
suspension to just below the ride height. 4. Install the J 8001 - indicator , or suitable dial indicator in
a way to measure the vertical lash in the ball joint.
Caution: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that
the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD).
Gently lift or pry the suspension to induce ball joint movement.
5. If the dial indicator is reading more than 0.50 mm (0.020 in) replace the lower ball joint. Refer to
Lower Control Arm Ball Joint Replacement
(4WD, 2WD, Z71) (See: Service and Repair/Lower Control Arm Ball Joint Replacement)Lower
Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) (See: Service and Repair/Front
Suspension/Lower Control Arm Ball Joint Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing
and Inspection > Ball Joint Inspection (Lower Ball Joint) > Page 8136
Ball Joint: Testing and Inspection Ball Joint Inspection (Upper Ball Joint)
Ball Joint Inspection (Upper Ball Joint)
Special Tools
J 8001 - Dial Indicator Set
Note: *
The vehicle must rest on a level surface.
* The vehicle must be stable. Do not rock the vehicle on the floor stands.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Clean and inspect the ball joint seals for cuts or tears.
If the ball joint seals are damaged, replace the ball joint. Refer to Upper Control Arm
Replacement (2WD, Z85, ZQ8) (See: Control Arm/Service and Repair/Front Suspension/Upper
Control Arm Replacement)Upper Control Arm Replacement (4WD, 2WD, Z71) (See: Control
Arm/Service and Repair/Upper Control Arm Replacement).
3. Support the lower control arm with a floor stand as far outboard as possible and raise the
suspension to just below ride height. 4. Install J 8001 - indicator , or suitable dial indicator in a way
to measure the vertical lash in the ball joint.
Caution: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that
the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD).
5. Apply downward force to the upper control arm and zero the indicator. 6. Apply upward force to
the upper control arm and check the dial indicator. 7. If the dial indicator reading is more than 0.50
mm (0.020 in) , replace the upper control arm. Refer to Upper Control Arm Replacement (2WD,
Z85, ZQ8) (See: Control Arm/Service and Repair/Front Suspension/Upper Control Arm
Replacement)Upper Control Arm Replacement (4WD, 2WD, Z71) (See: Control Arm/Service and
Repair/Upper Control Arm Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service
and Repair > Front Suspension
Ball Joint: Service and Repair Front Suspension
Lower Control Arm Ball Joint Replacement
Lower Control Arm Ball Joint Replacement (2WD, Z85, ZQ8)
Removal Procedure
1. Remove the steering knuckle. Refer to Steering Knuckle Replacement (See: Front Steering
Knuckle/Service and Repair).
2. Remove the ball joint nuts and bolts from the lower control arm. Discard the nuts and bolts. 3.
Remove the ball joint from the lower control arm.
Installation Procedure
1. Install the ball joint to the lower control arm.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service
and Repair > Front Suspension > Page 8139
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the new ball joint nuts and bolts to the lower control arm and tighten the nuts to 60 Nm (44
lb ft). 3. Install the steering knuckle. Refer to Steering Knuckle Replacement (See: Front Steering
Knuckle/Service and Repair). 4. Verify the wheel alignment. Refer to Wheel Alignment
Specifications (See: Alignment/Specifications).
Upper Control Arm Ball Joint Replacement
Upper Control Arm Ball Joint Replacement (2WD, Z85, ZQ8)
Special Tools
J-42188-B Ball Joint Separator
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Support the
lower control arm with a suitable jack stand. 4. Disconnect the front brake hose from the upper
control arm. Refer to Front Brake Hose Replacement (See: Brakes and Traction
Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement).
5. Remove the wheel speed sensor bracket bolt. 6. Disconnect the wheel speed sensor brackets.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service
and Repair > Front Suspension > Page 8140
7. Remove the nut from the upper ball joint. Discard the nut. 8. Disconnect the ball joint from the
steering knuckle using the J-42188-B .
9. Remove the ball joint nuts and bolts from the upper control arm. Discard the nuts and bolts.
10. Remove the ball joint from the upper control arm.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service
and Repair > Front Suspension > Page 8141
1. Install the ball joint to the upper control arm. 2. Install the replacement bolts to the upper control
arm.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the nuts to the bolts and tighten 16 Nm (12 lb ft). 4. Connect the ball joint to the steering
knuckle.
5. Install the new nut to the upper ball joint and tighten to 100 Nm (74 lb ft). 6. Connect the wheel
speed sensor brackets. 7. Install the wheel speed sensor bracket bolt and tighten to 20 Nm (15 lb
ft). 8. Connect the front brake hose to the upper control arm. Refer to Front Brake Hose
Replacement (See: Brakes and Traction Control/Hydraulic
System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement).
9. Remove the support from the lower control arm.
10. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair). 11. Lower the vehicle. 12. Verify the wheel alignment. Refer
to Wheel Alignment Specifications (See: Alignment/Specifications).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service
and Repair > Front Suspension > Page 8142
Ball Joint: Service and Repair Lower Control Arm Ball Joint Replacement
Lower Control Arm Ball Joint Replacement (4WD, 2WD, Z71)
Removal Procedure
1. Remove the steering knuckle. Refer to Steering Knuckle Replacement (See: Front Steering
Knuckle/Service and Repair).
2. Remove the ball joint nuts and bolts from the lower control arm. Discard the nuts and bolts. 3.
Remove the ball joint from the lower control arm.
Installation Procedure
1. Install the ball joint to the upper control arm.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service
and Repair > Front Suspension > Page 8143
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the new ball joint nuts and bolts to the lower control arm and tighten to 64 Nm (47 lb ft). 3.
Install the steering knuckle. Refer to Steering Knuckle Replacement (See: Front Steering
Knuckle/Service and Repair). 4. Verify the wheel alignment. Refer to Wheel Alignment
Specifications (See: Alignment/Specifications).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service
and Repair > Front Suspension > Page 8144
Ball Joint: Service and Repair Upper Control Arm Ball Joint Replacement
Upper Control Arm Ball Joint Replacement (4WD, 2WD, Z71)
Special Tools
J-42188-B Ball Joint Separator
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Support the
lower control arm with a suitable jack stand. 4. Disconnect the front brake hose from the upper
control arm. Refer to Front Brake Hose Replacement (See: Brakes and Traction
Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement).
5. Remove the wheel speed sensor bracket bolt. 6. Disconnect the wheel speed sensor brackets.
7. Disconnect the upper control arm from the ball stud by removing the retention nuts. Discard the
nuts. 8. Remove the nut from the upper ball joint. Discard the nut. 9. Disconnect the ball joint from
the steering knuckle using the J-42188-B .
10. Remove the ball joint from the steering knuckle.
Installation Procedure
1. Install the ball joint to the steering knuckle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the new nut to the upper ball joint and tighten to 75 Nm (55 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service
and Repair > Front Suspension > Page 8145
3. Connect the upper control arm to the ball stud by installing the retention nuts. Tighten the nut to
47 Nm (35 lb ft). 4. Connect the wheel speed sensor brackets. 5. Install the wheel speed sensor
bracket bolt and tighten to 20 Nm (15 lb ft). 6. Connect the front brake hose to the upper control
arm. Refer to Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic
System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement).
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair). 8. Remove the lower control arm support. 9. Lower the
vehicle.
10. Verify the wheel alignment. Refer to Wheel Alignment Specifications (See:
Alignment/Specifications).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing >
Component Information > Service and Repair
Control Arm Bushing: Service and Repair
Front Lower Control Arm Bushing Replacement
Tools Required
J 41805 Ball Joint Remover/Installer
Removal Procedure
1. Remove the front drive axle, if equipped. Refer to Differential Carrier Assembly Replacement
(See: Transmission and Drivetrain/Differential
Assembly/Differential Carrier/Service and Repair).
2. Remove the lower control arm. Refer to Lower Control Arm Replacement (2WD, Z85, ZQ8)
(See: Service and Repair/Front Suspension/Lower
Control Arm Replacement).
3. Before removing the bushing, measure and record the distance from the bushing flange to the
bracket. This will be the distance that the new
bushing will be installed to.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing >
Component Information > Service and Repair > Page 8150
4. Using the J 41805 (1), remove the rear bushing.
Installation Procedure
1. Using the J 41805 (1), install the rear bushing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing >
Component Information > Service and Repair > Page 8151
2. Install the rear bushing to the predetermined measurement taken earlier. 3. Install the lower
control arm. Refer to Lower Control Arm Replacement (2WD, Z85, ZQ8) (See: Service and
Repair/Front Suspension/Lower
Control Arm Replacement).
4. Install the front drive axle, if equipped. Refer to Differential Carrier Assembly Replacement (See:
Transmission and Drivetrain/Differential
Assembly/Differential Carrier/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Service and Repair > Crossmember Replacement
Cross-Member: Service and Repair Crossmember Replacement
Crossmember Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle
Lifting/Service and Repair).
2. Remove the crossmember mounting nuts and bolts. 3. Remove the crossmember from the
vehicle.
Installation Procedure
1. Install the crossmember to the vehicle. 2. Perform the following procedure before installing the
bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Service and Repair > Crossmember Replacement > Page 8156
* Remove all traces of the original adhesive patch.
* Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry.
* Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the bolts and the nuts and tighten to 60 Nm (44 lb ft). 4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Service and Repair > Crossmember Replacement > Page 8157
Cross-Member: Service and Repair Transmission Support Crossmember Replacement
Transmission Support Crossmember Replacement (2WD)
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle
Lifting/Service and Repair). 2. Support the transmission with a suitable stand or jack.
3. Remove the nuts retaining the transmission mount to the transmission support. Refer to
Transmission Mount Replacement (2WD) (See:
Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Mount/Service and
Repair)Transmission Mount Replacement (4WD) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Transmission Mount/Service and Repair) for the 4L60E/4L65E
transmission or Transmission Mount Replacement (RPO Z71) (See: Transmission and
Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission
Mount Replacement (4WD) (See: Transmission and Drivetrain/Manual
Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount
Replacement (RPO Z85 and ZQ8) (See: Transmission and Drivetrain/Manual
Transmission/Transaxle/Transmission Mount/Service and Repair) for the Aisin AR5 transmission.
4. Raise the transmission.
5. Remove the vertical bolts retaining the transmission support to the frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Service and Repair > Crossmember Replacement > Page 8158
6. Remove the horizontal nuts and the bolts retaining the transmission support to the frame. 7.
Remove the transmission support from the frame.
Installation Procedure
1. Install the transmission support to the frame. 2. Loose install the horizontal nuts and the bolts
retaining the transmission support to the frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Service and Repair > Crossmember Replacement > Page 8159
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Loose install the vertical bolts retaining the transmission support to the frame.
* Tighten the horizontal nuts to 50 Nm (37 lb ft).
* Tighten the vertical bolts to 100 Nm (74 lb ft).
4. Lower the transmission.
5. Install the nuts to the transmission mount. Refer to Transmission Mount Replacement (2WD)
(See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount
Replacement (4WD) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Transmission Mount/Service and Repair) for the 4L60E/4L65E
transmission or Transmission Mount Replacement (RPO Z71) (See: Transmission and
Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair )Transmission
Mount Replacement (4WD) (See: Transmission and Drivetrain/Manual
Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount
Replacement (RPO Z85 and ZQ8) (See: Transmission and Drivetrain/Manual
Transmission/Transaxle/Transmission Mount/Service and Repair) for the Aisin AR5 transmission.
6. Remove the stand or jack. 7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair
Front Steering Knuckle: Service and Repair
Steering Knuckle Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Support the
lower control arm with a suitable jack.
Note: In the following service procedure, it is NOT necessary to separate the brake caliper and
mounting bracket. Remove them as an assembly. Support the assembly with mechanics wire or
equivalent.
4. Remove the brake caliper assembly and relocate to the side. Refer to Brake Caliper Bracket
Replacement (See: Brakes and Traction Control/Disc
Brake System/Brake Caliper/Service and Repair/Brake Caliper Bracket Replacement).
Note: Perform the following service procedure if the vehicle is equipped with 4WD. If the vehicle
does not have 4WD, proceed to Step 6.
5. Separate the front wheel drive shaft from the steering knuckle. Refer to Wheel Drive Shaft
Replacement (See: Transmission and Drivetrain/Drive
Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair).
6. Remove the speed senor wiring harness from the retaining clips on the upper control arm and
frame. 7. Remove the outer tie rod end from the knuckle. Refer to Steering Linkage Outer Tie Rod
Replacement (See: Steering/Tie Rod/Service and
Repair/Steering Linkage Outer Tie Rod Replacement).
8. Separate the upper ball joint from the knuckle. Refer to Upper Control Arm Ball Joint
Replacement (2WD, Z85, ZQ8) (See: Ball Joint/Service
and Repair/Front Suspension/Upper Control Arm Ball Joint Replacement)Upper Control Arm Ball
Joint Replacement (4WD, 2WD, Z71) (See: Ball Joint/Service and Repair/Upper Control Arm Ball
Joint Replacement).
9. Separate the lower ball joint from the knuckle. Refer to Lower Control Arm Ball Joint
Replacement (4WD, 2WD, Z71) (See: Ball Joint/Service
and Repair/Lower Control Arm Ball Joint Replacement)Lower Control Arm Ball Joint Replacement
(2WD, Z85, ZQ8) (See: Ball Joint/Service and Repair/Front Suspension/Lower Control Arm Ball
Joint Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair > Page 8163
Note: Remove the wheel hub and bearing assembly and knuckle as a unit.
10. Remove the knuckle from the upper and lower control arms. 11. Remove the wheel hub and
bearing assembly from the knuckle. Refer to Front Wheel Bearing and Hub Replacement (See:
Wheel
Bearing/Service and Repair).
Installation Procedure
1. Install the wheel hub and bearing assembly onto the knuckle. Refer to Front Wheel Bearing and
Hub Replacement (See: Wheel Bearing/Service
and Repair).
2. Install the lower control arm/ball joint into the knuckle. Refer to Lower Control Arm Ball Joint
Replacement (4WD, 2WD, Z71) (See: Ball
Joint/Service and Repair/Lower Control Arm Ball Joint Replacement)Lower Control Arm Ball Joint
Replacement (2WD, Z85, ZQ8) (See: Ball Joint/Service and Repair/Front Suspension/Lower
Control Arm Ball Joint Replacement).
Note: The following service procedure is for vehicles equipped with 4WD only. If the vehicle is not
equipped with 4WD, proceed to Step 4.
3. Install the wheel drive shaft into the knuckle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair > Page 8164
4. Install the upper control arm/ball joint into the knuckle. Refer to Upper Control Arm Ball Joint
Replacement (2WD, Z85, ZQ8) (See: Ball
Joint/Service and Repair/Front Suspension/Upper Control Arm Ball Joint Replacement)Upper
Control Arm Ball Joint Replacement (4WD, 2WD, Z71) (See: Ball Joint/Service and Repair/Upper
Control Arm Ball Joint Replacement).
5. Install the outer tie rod end into the knuckle. Refer to Steering Linkage Outer Tie Rod
Replacement (See: Steering/Tie Rod/Service and
Repair/Steering Linkage Outer Tie Rod Replacement).
6. Install the speed senor wiring harness in the retaining clips on the upper control arm and frame.
7. Install the brake caliper mounting bracket. Refer to Brake Caliper Bracket Replacement (See:
Brakes and Traction Control/Disc Brake
System/Brake Caliper/Service and Repair/Brake Caliper Bracket Replacement).
8. Install the wheel drive shaft retaining nut to specifications. Refer to Wheel Drive Shaft
Replacement (See: Transmission and Drivetrain/Drive
Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair).
9. Remove the support from the lower control arm.
10. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair) 11. Remove the support and lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering
Angle Sensor > Component Information > Diagrams
Steering Angle Sensor: Diagrams
Component Connector End Views
Steering Wheel Position Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering
Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower
Bearing Replacement
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft
Lower Bearing Replacement
Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering
Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower
Bearing Replacement > Page 8171
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering
Steering Wheel Position Sensor Centering
Removal Procedure
Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE
removing the sensor from the steering column. Once you have identified the steering wheel
position sensor, follow the instructions listed in the removal procedure.
1. Verify the type of steering wheel position sensor.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right.
Important: If reusing the existing sensor, you do not have to align the sensor before removal.
Centering is not required when it is time to reinstall.
3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing
assembly. 5. To install the sensor, proceed to step 1 in the installation section.
6. From the technicians point of view, the FRONT of the sensor will have:
* A foam ring (2)
* A pin hole (1) for centering the pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff
(3) before removing the sensor. Failure to do so will cause misalignment when installing the
sensor. A new sensor will be required if misaligned.
7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the
sensor. 9. Remove the sensor from the adapter and bearing assembly.
10. To install the sensor, proceed to step 5 in the installation procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering
Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower
Bearing Replacement > Page 8172
11. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note the location of the pin hole.
12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing
assembly. 14. To install the sensor, proceed to step 9 in the installation procedure.
15. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note location of the pin hole.
* A sensor clip in FRONT of the sensor
16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18.
Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to
step 13 in the installation procedure.
20. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (3)
* A pin hole (1) for the centering pin-Note the location of the pin hole.
* An alignment mark (2) on the flush rotor flange cuff (3) for installation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering
Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower
Bearing Replacement > Page 8173
21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing
assembly. 23. To install the sensor, proceed to step 17 in the installation procedure.
24. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (4)
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* An alignment mark (3) on the flush rotor flange cuff (4) for installation
* A foam ring (1)
25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing
assembly. 27. To install the sensor, proceed to step 21 in the installation procedure.
Installation Procedure
Important: If reusing the existing sensor, no centering of the sensor is required.
1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin
until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1)
connector will be on your right.
From the technicians point of view, the BACK of the sensor (2) connector will be on your left.
3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 4. Install the connector to the sensor.
5. From the technicians point of view, the FRONT of the sensor will have:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering
Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower
Bearing Replacement > Page 8174
* A foam ring (4)
* A pin hole (7) for the centering pin-Note the location of the pin hole.
* A flushed rotor flange cuff (6)
* An alignment mark (5) for installation
6. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* A foam ring (3)
* An alignment tab (2) for installing into the adapter and bearing assembly
* A view of the inside of the connector
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 8. Install the connector to the sensor.
9. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A raised rotor flange cuff (5)
* An alignment mark (4) for installation
10. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 12. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering
Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower
Bearing Replacement > Page 8175
13. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A raised rotor flange cuff (4)
* An alignment mark (3) for installation
14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 16. Install the connector to the sensor.
17. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
* An alignment mark (3) for installation
18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 20. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering
Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower
Bearing Replacement > Page 8176
21. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A flush rotor flange cuff (5)
* An alignment mark (4) for installation
* A foam ring (6)
22. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 24. Install the connector to the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing
> Component Information > Service and Repair > Front Suspension
Stabilizer Bushing: Service and Repair Front Suspension
Stabilizer Shaft Insulator Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing
> Component Information > Service and Repair > Front Suspension > Page 8182
Stabilizer Bushing: Service and Repair Rear Suspension
Stabilizer Shaft Insulator Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Support the rear axle at curb height.
3. Remove the stabilizer shaft insulator bracket mounting bolts. 4. Remove the stabilizer shaft
insulator brackets. 5. Remove the stabilizer shaft insulators.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing
> Component Information > Service and Repair > Front Suspension > Page 8183
1. Install the stabilizer shaft insulators to the stabilizer shaft. 2. Install the stabilizer shaft insulator
brackets to the rear axle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the stabilizer shaft bracket mounting bolts and tighten to 50 Nm (37 lb ft). 4. Remove the
rear axle support. 5. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension
Stabilizer Link: Service and Repair Front Suspension
Stabilizer Shaft Link Replacement (ZQ8, Z85)
Stabilizer Shaft Link Replacement (ZQ8, Z85)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel
Removal and Installation (See: Wheels and Tires/Service and Repair).
3. Using the proper size wrench, hold the link ball stud while removing the link nut. 4. Remove the
retaining nut from the stabilizer shaft and the lower control arm.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension > Page 8188
5. Remove the stabilizer link from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension > Page 8189
1. Install the stabilizer shaft link on the lower control arm and stabilizer shaft.
2. Hand tighten the stabilizer shaft link nuts
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension > Page 8190
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Using the proper size wrench to hold the link ball joint, tighten the link nut to 44 Nm (32 lb ft). 4.
Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) 5. Remove the support and lower the vehicle. Refer to
Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair).
Stabilizer Shaft Link Replacement (Z71)
Stabilizer Shaft Link Replacement (Z71)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair).
3. Remove the link nut (1) at the lower control arm. 4. Using the proper size wrench to hold the link
ball stud, remove the link nut (2) at the stabilizer shaft.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension > Page 8191
5. Remove the stabilizer shaft link from the lower control arm and stabilizer shaft.
Installation Procedure
1. Install the stabilizer shaft link into the lower control arm and the stabilizer shaft.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension > Page 8192
2. Hand tighten the lower link nut (1) at the lower control arm. 3. Hand tighten the link nut at the
stabilizer shaft (2).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Using the proper size wrench to hold the link ball stud, tighten the link nut to 44 Nm (32 lb ft). 5.
Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) 6. Remove the support and lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension > Page 8193
Stabilizer Link: Service and Repair Rear Suspension
Stabilizer Shaft Link Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Support the rear axle at ride height.
Note: Do not attempt to hold the stabilizer shaft link near the boot. Use the hex feature on the end
of the stud. Failure to do so could damage the boot.
3. Remove the stabilizer shaft link upper nut. 4. Remove the stabilizer shaft link lower nut. 5.
Remove the stabilizer shaft link.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension > Page 8194
Note: Do not attempt to hold the stabilizer shaft link near the boot. Use the hex feature on the end
of the stud. Failure to do so could damage the boot.
1. Install the stabilizer shaft link.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the stabilizer shaft link mounting nuts.
* Tighten the stabilizer bar link lower mounting nut to 44 Nm (32 lb ft).
* Tighten the stabilizer bar link upper mounting nut to 44 Nm (32 lb ft).
3. Remove the axle support. 4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle >
Component Information > Service and Repair > Spring Shackle Replacement
Shackle: Service and Repair Spring Shackle Replacement
Spring Shackle Replacement
Special Tools
J 36660-A Angle Meter
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair).
2. Support the rear axle at ride height. 3. Remove the shackle nut and the bolt from the frame. 4.
Remove the shackle nut and the bolt from the spring. 5. Remove the shackle assembly from the
vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle >
Component Information > Service and Repair > Spring Shackle Replacement > Page 8200
1. Install the shackle assembly to the spring.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the shackle nut and bolt to the spring and tighten to 85 Nm (63 lb ft). 3. Install the shackle
nut and bolt to the frame and tighten to 85 Nm (63 lb ft). 4. Remove the rear axle support. 5. Lower
the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle >
Component Information > Service and Repair > Spring Shackle Replacement > Page 8201
Shackle: Service and Repair Rear Spring Shackle Bushing Replacement
Rear Spring Shackle Bushing Replacement
Tools Required
J 21474-01 Control Arm Bushing Service Kit
Removal Procedure
1. Remove the spring shackle. Refer to Spring Shackle Replacement (See: Spring Shackle
Replacement). 2. Remove the spare tire when servicing the left side bushing.
3. Use a blunt punch to straighten out the bushing flange that comes through the inner frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle >
Component Information > Service and Repair > Spring Shackle Replacement > Page 8202
4. Remove the spring shackle bushing using J 21474-01 .
Installation Procedure
1. Install the new spring shackle bushing using J 21474-01 .
2. Pull the spring shackle bushing into the frame rail until the flanged portion of the spring shackle
bushing is flush with the rail.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle >
Component Information > Service and Repair > Spring Shackle Replacement > Page 8203
3. Use a blunt punch to stake or flare the spring shackle bushing inner flange. 4. Install the spare
tire when servicing the left side bushing. 5. Install the spring shackle. Refer to Spring Shackle
Replacement (See: Spring Shackle Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information
Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock
Absorber/Strut Leakage Information
INFORMATION
Bulletin No.: 05-03-08-002C
Date: October 16, 2009
Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks
Models:
2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures.
Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension).
This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage.
Improper diagnosis may lead to components being replaced that are within the manufacturer's
specification. Shock absorbers and strut assemblies are fluid-filled components and will normally
exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the
shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage.
Use the following information to determine if the condition is normal acceptable seepage or a
defective component.
Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to
this oil film. Often this film and dust can be wiped off and will not return until similar mileage is
accumulated again.
Inspection Procedure
Note
The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform
the following inspection procedure.
Use the following descriptions and graphics to determine the serviceability of the component.
Shock Absorbers
Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage.
1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the
shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or
less of the lower shock tube (A) and originating from the shaft seal.
Replace shock absorbers displaying conditions 3 and 4 levels of leaks.
3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet
film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal.
Coil-over Shock Absorber
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information > Page 8208
Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage.
1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock
absorber components and not originating from the
shaft seal (located at the top of the coil-over shock tube).
2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the
shaft seal.
Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks.
3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet
film of oil covering the shock absorber tube and pooling in the spring seat and originating from the
shaft seal.
Struts
Do Not Replace Struts displaying condition 1 or 2 levels of seepage.
1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not
originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and
originating from the shaft seal.
Replace Struts displaying conditions 3 and 4 levels of leaks.
3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the
strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and
originating from the shaft seal.
Correction
Use the information published in SI for diagnosis and repair.
Use the applicable published labor operation.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Shock Absorber
Suspension Strut / Shock Absorber: Service and Repair Front Suspension Shock Absorber
Shock Absorber Disposal
Shock Absorber Disposal
Warning
Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside
the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out
with extreme force which may result in personal injury.
Warning
To prevent personal injury, wear safety glasses when centerpunching and drilling the shock
absorber. Use care not to puncture the shock absorber tube with the centerpunch.
1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2.
Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely
extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill
bit. Gas or a gas/oil mixture will exhaust when the drill bit
penetrates the shock absorber. Use shop towels in order to contain the escaping oil.
4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in
the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the
drill bit penetrates the
shock absorber. Use shop towels in order to contain the escaping oil.
6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally
with the holes down. Move the rod (1) in and out
of the tube (3) to completely drain the oil from the shock absorber.
Shock Absorber Replacement
Shock Absorber Replacement (2WD, Z85, ZQ8)
Special Tools
J 45400 Strut Spring Compressor
Removal Procedure
Caution: The front shock absorbers of the vehicle are multifunctional. In addition to contributing to a
smooth ride they also provide the only stop to the front suspension when fully extended. Therefore,
when servicing the shock absorber, service replacement shock absorbers must be equivalent to
original shock absorbers in both extended length and strength. Use of shocks not complying to
original equipment or strength could result in suspension over-travel or shock breakage.
Suspension over-travel may result in suspension component breakage.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Shock Absorber > Page 8211
1. Remove the absorber/spring assembly upper mounting nuts.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 3. Remove the tire and wheel. Refer to Tire and Wheel
Removal and Installation (See: Wheels and Tires/Service and Repair). 4. Remove the
absorber/spring assembly bolt and nut. 5. Remove the front stabilizer link. Refer to Stabilizer Shaft
Link Replacement (ZQ8, Z85) (See: Stabilizer Bar/Stabilizer Link/Service and
Repair/Front Suspension/Stabilizer Shaft Link Replacement (ZQ8, Z85))Stabilizer Shaft Link
Replacement (Z71) (See: Stabilizer Bar/Stabilizer Link/Service and Repair/Front
Suspension/Stabilizer Shaft Link Replacement (Z71)).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Shock Absorber > Page 8212
6. Remove the absorber/spring assembly from the vehicle.
Caution: Use care when handling the coil springs in order to avoid chipping or scratching the
coating. Damage to the coating will result in premature failure of the coil springs.
7. Install the absorber/spring assembly (2) into the J 45400 (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Shock Absorber > Page 8213
Note: The spring is compressed when the shock absorber moves freely.
8. Turn the spring compressor forcing screw (1) until the coil spring (2) is compressed.
9. Remove the absorber upper retaining nut, bushings, and washers.
10. Remove the absorber from the assembly. 11. Do not remove the spring from the J 45400 .
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Shock Absorber > Page 8214
1. Install the absorber to the J 45400 (1). 2. Install the absorber bushings and washers (2).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: Ensure that the absorber bushings and tennon align correctly with the mounting bracket
before securing the retaining nut.
3. Install the absorber retaining nut and tighten to 20 Nm (15 lb ft).
4. Remove the absorber/spring assembly (2) from the J 45400 (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Shock Absorber > Page 8215
5. Install the absorber/spring assembly to the vehicle.
6. Install the absorber/spring assembly bolt and nut and tighten to 110 Nm (81 lb ft). 7. Install the
front stabilizer link. Refer to Stabilizer Shaft Link Replacement (ZQ8, Z85) (See: Stabilizer
Bar/Stabilizer Link/Service and
Repair/Front Suspension/Stabilizer Shaft Link Replacement (ZQ8, Z85))Stabilizer Shaft Link
Replacement (Z71) (See: Stabilizer Bar/Stabilizer Link/Service and Repair/Front
Suspension/Stabilizer Shaft Link Replacement (Z71)).
8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair). 9. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Shock Absorber > Page 8216
10. Install the absorber/spring assembly upper mounting nuts and tighten to 27 Nm (20 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Shock Absorber > Page 8217
Suspension Strut / Shock Absorber: Service and Repair Rear Suspension Shock Absorber
Shock Absorber Replacement
Shock Absorber Replacement
Removal Procedure
Caution: The front shock absorbers of the vehicle are multifunctional. In addition to contributing to a
smooth ride they also provide the only stop to the front suspension when fully extended. Therefore,
when servicing the shock absorber, service replacement shock absorbers must be equivalent to
original shock absorbers in both extended length and strength. Use of shocks not complying to
original equipment or strength could result in suspension over-travel or shock breakage.
Suspension over-travel may result in suspension component breakage.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Support the rear axle at ride height.
3. Remove the upper absorber bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Shock Absorber > Page 8218
4. Remove the lower absorber nut and the bolt. 5. Remove the absorber.
Installation Procedure
1. Install the absorber.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the upper absorber bolts and tighten to 35 Nm (26 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Shock Absorber > Page 8219
3. Install the lower absorber bolt and nut and tighten the nut to 95 Nm (70 lb ft). 4. Remove the rear
axle support. 5. Lower the vehicle.
Shock Absorber Disposal
Shock Absorber Disposal
Warning
Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside
the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out
with extreme force which may result in personal injury.
Warning
To prevent personal injury, wear safety glasses when centerpunching and drilling the shock
absorber. Use care not to puncture the shock absorber tube with the centerpunch.
1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2.
Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely
extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill
bit. Gas or a gas/oil mixture will exhaust when the drill bit
penetrates the shock absorber. Use shop towels in order to contain the escaping oil.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Shock Absorber > Page 8220
4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in
the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the
drill bit penetrates the
shock absorber. Use shop towels in order to contain the escaping oil.
6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally
with the holes down. Move the rod (1) in and out
of the tube (3) to completely drain the oil from the shock absorber.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Service and Repair > Front Suspension
Suspension Travel Bumper: Service and Repair Front Suspension
Spring Bumper Replacement (Z71)
Spring Bumper Replacement (4WD, 2WD Z71)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair).
2. Remove the jounce bumper.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Service and Repair > Front Suspension > Page 8225
1. Install the jounce bumper. 2. Lower the vehicle.
Spring Bumper Replacement (Z85, ZQ8)
Spring Bumper Replacement (2WD, Z85, ZQ8)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair).
2. Remove the jounce bumper mounting bolts. 3. Remove the jounce bumper.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Service and Repair > Front Suspension > Page 8226
1. Install the jounce bumper.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the jounce bumper bolts and tighten to 32 Nm (24 lb ft). 3. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Service and Repair > Front Suspension > Page 8227
Suspension Travel Bumper: Service and Repair Rear Suspension
Spring Jounce Bumper Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair).
2. Remove the auxiliary jounce bumper mounting bolts. 2WD base and RPO ZQ8 suspension.
3. Remove the jounce bumper mounting bolts. 2WD base suspension.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Service and Repair > Front Suspension > Page 8228
4. Remove the jounce bumper mounting bolts. 4WD base suspension.
5. Remove the jounce bumper mounting bolts. 2WD RPO ZQ8 suspension.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Service and Repair > Front Suspension > Page 8229
6. Remove the jounce bumper mounting bolts. RPO Z71 suspension. 7. Remove the jounce
bumper.
Installation Procedure
1. Install the jounce bumper.
2. Install the jounce bumper mounting bolts. RPO Z71 suspension.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Service and Repair > Front Suspension > Page 8230
3. Install the jounce bumper mounting bolts. 2WD RPO ZQ8 suspension.
4. Install the jounce bumper mounting bolts. 4WD base suspension.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Service and Repair > Front Suspension > Page 8231
5. Install the jounce bumper mounting bolts. 2WD base suspension.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the auxiliary jounce bumper mounting bolts. 2WD base and RPO ZQ8 suspension.
Tighten the bolts to 50 Nm (37 lb ft).
7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service
and Repair > Torsion Bar Replacement
Torsion Bar: Service and Repair Torsion Bar Replacement
Torsion Bar Replacement
Removal Procedure
Caution: Use care when handling the torsion bars in order to avoid chipping or scratching the
coating. Damage to the coating will result in premature failure of the torsion bars.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and
Tires/Vehicle Lifting/Service and Repair). 2. Allow the front suspension to hang in the rebound
position. 3. Mark the adjuster bolt.
Note: To aid in re-assembly record the number of turns that are required to remove the adjuster
bolt.
4. Remove the adjuster bolt, spacer and adjuster nut.
Note: Take note that the torsion bars are specific to the left and right sides of the vehicle.
5. Remove the adjustment arms and torsion bars as a unit, moving it rearward to disengage the
lower control arm.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service
and Repair > Torsion Bar Replacement > Page 8236
1. Install the adjustment arms and torsion bars in relation to where the bars were removed. 2.
Install the adjustment arm to the torsion bar and slide the torsion bar forward until the torsion bar
fully engages the lower control arm. 3. Install the adjuster bolt, spacer and adjuster nut. 4. Lower
the vehicle. 5. Check the Z-Height. Refer to Trim Height Specifications (See: Specifications/Trim
Height Specifications).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service
and Repair > Torsion Bar Replacement > Page 8237
Torsion Bar: Service and Repair Torsion Bar Anchor Replacement
Torsion Bar Anchor Replacement
Removal Procedure
1. Remove the torsion bar. Refer to Torsion Bar Replacement (See: Torsion Bar Replacement).
2. Remove the nuts and the bolts from the lower control arm.
3. Remove the torsion bar anchor.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service
and Repair > Torsion Bar Replacement > Page 8238
1. Install the torsion bar anchor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the nuts and the bolts to the lower control arm and tighten to 80 Nm (59 lb ft). 3. Install the
torsion bar. Refer to Torsion Bar Replacement (See: Torsion Bar Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Testing and Inspection
Wheel Bearing: Testing and Inspection
Wheel Bearings Diagnosis
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Testing and Inspection > Page 8242
Wheel Bearing: Service and Repair
Front Wheel Bearing and Hub Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction
Control/Service Precautions/Technician Safety Information/Brake Dust Warning ).
Warning: Refer to ABS Component Handling Warning (See: Brakes and Traction Control/Service
Precautions/Technician Safety Information/ABS Component Handling Warning).
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle
Lifting/Service and Repair). 2. Remove the front brake caliper. Refer to Brake Caliper Replacement
(See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Brake Caliper Replacement).
3. Remove the speed sensor electrical connector and the mounting bracket. Refer to Front Wheel
Speed Sensor Replacement (See: Brakes and
Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and
Repair/Front Wheel Speed Sensor Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Testing and Inspection > Page 8243
4. To ensure the ease of removal, bundle speed sensor wiring harness so not to have it entangled
in any of the suspension components.
Note: The following service procedure applies to those vehicles that are equipped with 4 wheel
drive ONLY.
5. Remove the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Front
Steering Knuckle/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Testing and Inspection > Page 8244
6. Remove the mounting bolts for the wheel bearing/hub, brake rotor assembly.
7. Remove the wheel bearing/hub, brake rotor assembly from the steering knuckle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Testing and Inspection > Page 8245
Note: Perform the following service procedure with the brake rotor on a flat surface.
8. Remove the mounting bolt from the wheel bearing/hub, to the brake rotor.
Note: The splash shield will come off the steering knuckle when the wheel bearing/hub, brake rotor
is removed.
9. Remove the wheel bearing/hub from the brake rotor.
10. Clean the contact area between the wheel bearing/hub and the brake rotor.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Testing and Inspection > Page 8246
1. Position the wheel bearing/hub assembly on the brake rotor. 2. Install the mounting bolts from
the wheel bearing/hub assembly to the brake rotor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: The following service procedure is to be performed on a flat surface and to ensure that the
brake rotor is securely attached to the hub assembly prior to the final torquing procedure. DO NOT
use air tools of any type for this procedure.
3. Tighten the bolts in crisscross pattern. Tighten the mounting bolts to 20 Nm (15 lb ft). 4. Install
the backing plate to the wheel bearing/hub, brake rotor assembly.
Note: The following service procedure applies to those vehicles that are equipped with 4 wheel
drive ONLY.
5. Install the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Front
Steering Knuckle/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Testing and Inspection > Page 8247
6. Install the wheel bearing/hub, brake rotor assembly in the steering knuckle.
Note: When performing the following service procedure, DO NOT use air tools of any type to torque
the brake rotor to hub bolts.
7. Install the wheel bearing/hub, brake rotor mounting bolts and tighten to 125 Nm (92 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Testing and Inspection > Page 8248
8. Install the brake caliper mounting bracket to the steering knuckle.
9. Install the mounting bolts for the brake caliper mounting bracket and tighten to 175 Nm (129 lb
ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Testing and Inspection > Page 8249
10. Position a large screwdriver or pry bar in the cooling fins of the brake rotor and the brake
caliper mounting bracket.
Note: The following service procedure is to ensure that the brake rotor is seated properly on the
wheel bearing/hub assembly.
11. Tighten the mounting bolts for the brake rotor in sequence.
12. Using a torque wrench, tighten the mounting bolts to 110 Nm (81 lb ft). 13. Install the speed
sensor mounting bracket and re-connect the electrical connector. Refer to Front Wheel Speed
Sensor Replacement (See: Brakes
and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and
Repair/Front Wheel Speed Sensor Replacement).
14. Check for hub/rotor/bearing LRO specifications. Refer to Disc Brake Component Specifications
(See: Brakes and Traction Control/Disc Brake
System/Specifications/Disc Brake Component Specifications).
15. Install the brake caliper assembly. Refer to Brake Caliper Replacement (See: Brakes and
Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Brake Caliper Replacement).
16. Install the wheel speed sensor to the body. 17. Lower the vehicle. Refer to Lifting and Jacking
the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information
> Specifications
Axle Nut: Specifications
Drive Shaft Nut ....................................................................................................................................
.................................................... 260 Nm (191 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Service and Repair
Vehicle Lifting: Service and Repair
Lifting and Jacking the Vehicle
Danger: To avoid any vehicle damage, serious personal injury or death when major components
are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack
stands at the opposite end from which the components are being removed and strap the vehicle to
the hoist.
Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands
to support the vehicle when lifting the vehicle with a jack.
Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
Vehicle Lifting
* Ensure that the lifting equipment meets weight requirements and is in good working order. Always
follow the lift manufacturer's instructions.
* You may lift and support the front of the vehicle at the front suspension near the wheel
assemblies. Ensure that the arms of the front cradle are extended as close to the steering knuckle
as possible.
* Ensure that the vehicle is centered on the hoist before attempting to lift.
* When using a suspension-contact hoist, ensure that the rear cradle has adequate clearance for
the rear stabilizer bar.
* When lifting or jacking a vehicle, be certain that the lift pads do not contact the exhaust system,
brake pipes, cables, HVAC lines, wiring harnesses, fuel lines, or underbody. Such contact may
result in damage or unsatisfactory vehicle performance.
* When using a frame-contact hoist, only place the pads on flat surfaces. Do not place pads within
50 mm (2 in) of any radius.
* Before lifting the vehicle, verify that the vehicle loads are secure and equally distributed.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Service and Repair > Page 8258
* When major components are removed from the vehicle when supported on a hoist, support the
vehicle with jack stands at the opposite end from which the components are being removed and
secure the vehicle frame to the hoist pads nearest the component to be removed.
Vehicle Jacking
* Park the vehicle on a clean, hard, level surface before jacking the vehicle.
* Any time you lift the vehicle on one end, chock the wheels at the opposite end.
* Use jack stands in order to provide support.
* When supporting the vehicle using jack stands, place the jack stands under the side rails or the
axle.
* When lifting under the rear differential, do not allow the jack pad to contact the rear stabilizer bar
or mounting hardware.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires >
Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires >
Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor
System - TPM Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 8273
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 8274
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 8275
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 8276
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 8277
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement
Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and
Wheel Removal and Installation (See: Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service
and Repair/Removal and Replacement).
Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the
inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 Nm (62 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement >
Page 8280
Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting.
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and
Repair/Removal and Replacement).
Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor
unique identification code cannot be learned into the body control module (BCM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensors internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire
Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement >
Page 8281
Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement
Tire Valve Stem Grommet Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and
Wheel Removal and Installation (See: Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting:
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead
from the wheel.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the outside of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service
and Repair/Removal and Replacement).
Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure
Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all
residual liquid sealant from the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the
sensor grommet from the valve stem.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor
valve stem.
3. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement >
Page 8282
4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 Nm (62 lb in).
Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and
Repair/Removal and Replacement). 6. Install the tire/wheel assembly on the vehicle. Refer to Tire
and Wheel Removal and Installation (See: Service and Repair). 7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips
Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System
Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 8288
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 8289
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 8290
Customer TPMS Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 8291
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 8292
Frequently Asked Questions
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM
Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs >
Page 8305
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs >
Page 8306
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs >
Page 8307
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs >
Page 8308
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs >
Page 8309
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement
Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and
Wheel Removal and Installation (See: Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service
and Repair/Removal and Replacement).
Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the
inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 Nm (62 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 8312
Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting.
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and
Repair/Removal and Replacement).
Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor
unique identification code cannot be learned into the body control module (BCM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensors internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire
Pressure Indicator Sensor Learn (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 8313
Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement
Tire Valve Stem Grommet Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and
Wheel Removal and Installation (See: Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting:
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead
from the wheel.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the outside of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service
and Repair/Removal and Replacement).
Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure
Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all
residual liquid sealant from the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the
sensor grommet from the valve stem.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor
valve stem.
3. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 8314
4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 Nm (62 lb in).
Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and
Repair/Removal and Replacement). 6. Install the tire/wheel assembly on the vehicle. Refer to Tire
and Wheel Removal and Installation (See: Service and Repair). 7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component
Information > Service and Repair
Spare Tire: Service and Repair
Spare Tire Carrier Replacement
Removal Procedure
1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover
on the bumper and use the ignition key to remove
the lock.
Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools.
The use of air tools at high speeds will damage the spare tire hoist assembly.
2. Turn the hoist shaft counterclockwise to lower the spare tire to the ground. Continue to turn the
hoist shaft until the spare tire can be pulled out
from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary
latch is engaged causing the tire not to lower.
3. If the secondary latch is engaged and the cable end is visible, perform the following procedure:
1. Tighten the cable by turning the hoist shaft clockwise until you hear two clicks or feel it skip
twice. You cannot overtighten the cable. 2. Loosen the cable by turning the hoist shaft
counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the
spare tire can be removed. 4. If the spare tire cannot be lowered, turn the hoist shaft
counterclockwise until approximately 15 cm (6 in) of cable is exposed. 5. Raise and support the
vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 6. Place
a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission
jack under the secondary latch release button at the center of the spare tire. Arrange the arms of
the
transmission jack so they will support the tire after it has been released.
8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the
secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, turn the hoist shaft
counterclockwise until the tire is low enough to remove.
4. If the secondary latch is engaged and the cable end is not visible, perform the following
procedure:
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Place a transmission jack, or equivalent, under the spare tire. 3.
Position the center of the transmission jack under the secondary latch release button at the center
of the spare tire. Arrange the arms of the
transmission jack so they will support the tire after it has been released.
4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the
secondary latch. 5. Lower the tire and remove it from the jack.
5. Raise and support the vehicle if it is not already raised. Refer to Lifting and Jacking the Vehicle
(See: Vehicle Lifting/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component
Information > Service and Repair > Page 8319
6. Remove the spare tire hoist guide mounting bolt from the crossmember. 7. Remove the spare
tire hoist shaft guide.
8. Remove the bolt. 9. Remove the hoist from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component
Information > Service and Repair > Page 8320
1. Install the hoist.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt and tighten to 40 Nm (30 lb ft).
3. Install the spare tire hoist shaft guide. 4. Install the mounting bolt for the guide and tighten to 30
Nm (20 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component
Information > Service and Repair > Page 8321
5. Install the spare tire to the hoist.
Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools.
The use of air tools at high speeds will damage the spare tire hoist assembly.
6. Turn the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it
skips twice. You cannot overtighten the cable. 7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation
(RFV)
Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV)
INFORMATION
Bulletin No.: 00-03-10-006F
Date: May 04, 2010
Subject: Information on Tire Radial Force Variation (RFV)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009
and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION
Supercede: This bulletin is being revised to considerably expand the available information on
Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin
Number 00-03-10-006E (Section 03 - Suspension).
Important
- Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven
a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin
Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires.
- Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel
assemblies for each vehicle.
The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation
measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable
tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force
variation is highway speed shake on smooth roads.
Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out
of round and tire force variation. These three conditions are not necessarily related. All three
conditions must be addressed.
Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle,
two plane dynamic wheel balancers are readily available and can accurately correct any
imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer,
and proper balance weights, are all factors required for a quality balance. However, a perfectly
balanced tire/wheel assembly can still be "oval shaped" and cause a vibration.
Before balancing, perform the following procedures.
Tire and Wheel Diagnosis
1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are
centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while
shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick.
3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and
correct as necessary:
- Missing balance weights
- Bent rim flange
- Irregular tire wear
- Incomplete bead seating
- Tire irregularities (including pressure settings)
- Mud/ice build-up in wheel
- Stones in the tire tread
- Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to
diagnosing a smooth road shake condition.
4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a
sufficient distance on a known, smooth road
surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes
are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section
of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration
as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order
(one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high
enough in frequency that most humans can start to hear them at highway speeds, but are too high
to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment.
If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a
throbbing), chances are good that the vehicle could have driveline vibration. This type
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation
(RFV) > Page 8330
of vibration is normally felt more in the "seat of the pants" than the steering wheel.
5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found
at the end of this bulletin. This should be done
after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to
eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency
is prior to vehicle service and documents the amount of improvement occurring as the result of the
various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required.
A copy of the completed worksheet must be saved with the R.O. and a copy included with any
parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically
indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number
08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if
this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away
and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration
may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if
vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire
flat-spotting can be ruled out as the cause for vibration.
6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle
being parked for long periods of time and that the
nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information
on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment
Tires.
7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel
assembly on a known, calibrated, off-car dynamic
balancer.Make sure the mounting surface of the wheel and the surface of the balancer are
absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and
always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is
not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim
flange, remove all balance weights and rebalance to as close to zero as possible. If you can see
the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the
wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First
order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or
hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough,
it can be seen.
If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and
force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700
can address both (it is also a wheel balancer).
Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will
produce in one revolution under a constant load. Radial force variation is what the vehicle feels
because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not
under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel
assembly runout be within specification.
Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures
radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV
measurement at this point. To isolate the wheel, its runout must be measured. This can be easily
done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout
specification, the tire's RFV can then be addressed.
After measuring the tire/wheel assembly under load, and the wheel alone, the machine then
calculates (predicts) the radial force variation of the tire. However, because this is a prediction that
can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in
tire production, this type of service equipment should NOT be used to audit new tires. Rather, it
should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel
assembly.
Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of
finding the low point of the wheel (for runout) and the high point of the tire (for radial force
variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly
force variation.
The machine will simplify this process into easy steps. The following assembly radial force variation
numbers should be used as a guide:
When measuring RFV and match mounting tires perform the following steps.
Measuring Wheel Runout and Assembly Radial Force Variation
Important The completed worksheet at the end of this bulletin must be attached to the hard copy of
the repair order.
- Measure radial force variation and radial runout.
- If a road force/balancing machine is used, record the radial force variation (RFV) on the
worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the
front left corner. If the machine is not available and the EVA data suggests there is an issue, swap
the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem
still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those
tires onto the subject vehicle.
- If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the
worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040
in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive
customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to
have the lowest runout assembly to the front left corner. If the machine is not available and the
EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the
back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do
not exhibit the same frequency and swap those tires
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation
(RFV) > Page 8331
onto the subject vehicle.
- After match mounting, the tire/wheel assembly must be rebalanced.
If match mounting tires to in-spec wheels produces assembly values higher than these, tire
replacement may be necessary. Replacing tires at lower values will probably mean good tires are
being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect
force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring.
Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to
measuring.
Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are
more sensitive, and may require lower levels. Also, there are other tire parameters that equipment
such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be
contacted for further instructions.
Important
- When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's
center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are
secondary. Usually a back cone method to the machine should be used. For added accuracy and
repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This
system is offered by all balancer manufacturers in GM's dealer program.
- Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT
recommended, and may void the tire warranty. However, tires may have been ground by the tire
company as part of their tire manufacturing process. This is a legitimate procedure.
Steering Wheel Shake Worksheet
When diagnosing vibration concerns, use the following worksheet in conjunction with the
appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI.
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation
(RFV) > Page 8332
Refer to the appropriate section of SI for specifications and repair procedures that are related to the
vibration concern.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast
Aluminum Wheels
Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels
TECHNICAL
Bulletin No.: 05-03-10-003F
Date: April 27, 2010
Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels
Supercede: This bulletin is being revised to update the model years and the bulletin reference
information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension).
Condition
Some customers may comment on a low tire pressure condition.
Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel.
Cause
Porosity in the cast aluminum wheel may be the cause.
Notice
This bulletin specifically addresses issues related to the wheel casting that may result in an air
leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin
Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light
Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat).
Correction
1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service
procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the
tire/wheel assembly in a water bath, or use a spray bottle with soap
and water to locate the specific leak location.
Important
- If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim),
the wheel should be replaced.
- If two or more leaks are located on one wheel, the wheel should be replaced.
3. If air bubbles are observed, mark the location.
- If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks.
- If the leak is located on the aluminum wheel area, continue with the next step.
4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the
wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove
the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the
INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose
cleaner, such as 3M(R) General Purpose
Adhesive Cleaner, P/N 08984, or equivalent.
8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use
88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry.
Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging
the repair area may result in an air leak.
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast
Aluminum Wheels > Page 8337
10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire
Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on
the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and
inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the
tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire
and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty
one tube of adhesive/sealant per wheel repair.
For vehicles repaired under warranty, use:
One leak repair per wheel.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON
Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON
TECHNICAL
Bulletin No.: 08-03-10-006C
Date: April 27, 2010
Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated,
Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat)
Models:
2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 08-03-10-006B (Section 03 - Suspension).
Condition
Some customers may comment on a tire that slowly loses air pressure over a period of days or
weeks.
Cause
Abrasive elements in the environment may intrude between the tire and wheel at the bead seat.
There is always some relative motion between the tire and wheel (when the vehicle is driven) and
this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear
continues, there may also be intrusion at the tire/wheel interface by corrosive media from the
environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may
appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be
visible until the tire is dismounted from the wheel.
Notice
This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in
an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please
refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum
Wheels (Repair with Adhesive Sealant)
Correction
In most cases, this type of air loss can be corrected by following the procedure below.
Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to
repair the wheel with the procedure below.
Notice
The repair is no longer advised or applicable for chromed aluminum wheels.
1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and
Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to
be around the bead seat of the wheel, dismount the tire to examine
the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat
Corrosion
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Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 8342
Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel
flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for
additional information on possible wheel porosity issues.
3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a
rough or uneven surface that is difficult for the tire to
maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel
that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion
4. If corrosion is found on the wheel bead seat, measure the affected area as shown below.
- For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of
repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
- For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area
of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the
corrosion and any flaking paint. You should
remove the corrosion back far enough until you reach material that is stable and firmly bonded to
the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges
that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired
surface.
Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be
visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not
visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend
to the visible surfaces on the FACE of the wheel, that wheel must be replaced.
Important Remove ONLY the material required to eliminate the corrosion from the bead seating
surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as
smooth and level as possible.
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Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 8343
Acceptably Prepared (Cleaned-Up) Wheel Surface
6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially
available tire sealant such as Patch Brand Bead
Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will
permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this
sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat
7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel
Removal and Installation in SI.
Parts Information
Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at
www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
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Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 8344
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome
Wheel Staining/Pitting/Corrosion
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion
INFORMATION
Bulletin No.: 00-03-10-002F
Date: April 21, 2011
Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum
Wheels
Models:
2012 and Prior GM Cars and Trucks
Supercede: This bulletin is being revised to update model years, suggest additional restorative
products and add additional corrosion information. Please discard Corporate Bulletin Number
00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the
customer.
What is Chemical Staining of Chrome Wheels? Figure 1
Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an
example). These stains are frequently milky, black, or greenish in appearance. They result from
using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient
to clean wheels.
If the customer insists on using a wheel cleaner they should only use one that specifically states
that it is safe for chromed wheels and does not contain anything in the following list. (Dealers
should also survey any products they use during prep or normal cleaning of stock units for these
chemicals.)
- Ammonium Bifluoride (fluoride source for dissolution of chrome)
- Hydrofluoric Acid (directly dissolves chrome)
- Hydrochloric Acid (directly dissolves chrome)
- Sodium Dodecylbenzenesulfonic Acid
- Sulfamic Acid
- Phosphoric Acid
- Hydroxyacetic Acid
Notice
Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most
customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal.
Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the
paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car
warranty. Soap and water applied with a soft brush is usually all that is required to clean the
calipers.
Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean,
clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts,
lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to
the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the
damage around and under the wheel weight where the cleaner was incompletely flushed away.
Notice
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Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome
Wheel Staining/Pitting/Corrosion > Page 8350
Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome
wheels (or any wheels).
If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be
avoided.
For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and
Instructions below.
Warranty of Stained Chrome Wheels
Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome
wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were
returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be
charged back to the dealership. To assist the customer, refer to Customer Assistance and
Instructions below.
Pitting or Spotted Appearance of Chrome Wheels Figure 2
A second type or staining or finish disturbance may result from road chemicals, such as calcium
chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to
Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be
uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels
should be washed with mild soap and water and thoroughly rinsed as soon as conveniently
possible.
Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can
also stain chrome wheels. The staining will look like small pitting. This staining will usually be on
the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward
direction while being splashed by the road chemical. If a vehicle must be operated under such
conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed
as soon as conveniently possible.
Warranty of Pitted or Spotted Chrome Wheels
Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time.
Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish
and may cause damage if the wheels are not kept clean.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean if they are operating the vehicle in an area that
applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior
approval by the District Manager - Customer Care and Service Process (DM-CCSP).
"Stardust" Corrosion of Chrome Wheels Figure 3
A third type of finish disturbance results from prolonged exposure to brake dust and resultant
penetration of brake dust through the chrome. As brakes are applied hot particles of brake material
are thrown off and tend to be forced through the leading edge of the wheel spoke windows by
airflow. These
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome
Wheel Staining/Pitting/Corrosion > Page 8351
hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed
to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the
chrome leaving a pit or small blister in the chrome.
Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and
Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up
or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars
Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be
waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax
#M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake
dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may
be used. It will clean and shine the chrome and leave behind a wax coating that may help protect
the finish.
Warranty of Stardust Corroded Chrome Wheels
Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be
replaced one time.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust
build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care
and Service Process (DM-CCSP).
Customer Assistance and Instructions
GM has looked for ways customers may improve the appearance of wheels damaged by acidic
cleaners. The following product and procedure has been found to dramatically improve the
appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the
following:
Notice
THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN
EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE
APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL
REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED
INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER,
EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS
EXACTLY.
1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce
wheel staining. Flood all areas of the wheel with water
to rinse.
2. Dry the wheels completely.
Notice Begin with a small section of the wheel and with light pressure buff off polish and examine
results. ONLY apply and rub with sufficient force and time to remove enough staining that you are
satisfied with the results. Some wheels may be stained to the extent that you may only achieve a
50% improvement while others may be able to be restored to the original lustre. IN ALL CASES,
only apply until the results are satisfactory.
3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the
polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the
towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If
continued applications fail to improve the appearance
further discontinue use.
This procedure will improve the appearance of the wheels and may, with repeated applications,
restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above
procedure may marginally improve the condition but will not restore the finish or remove the pitting.
In this type of staining the wheel finish has actually been removed in spots and no manner of
cleaning will restore the finish.
†*We believe this source and their products to be reliable. There may be additional manufacturers
of such products/materials. General Motors does not endorse, indicate any preference for or
assume any responsibility for the products or material from this firm or for any such items that may
be available from other sources.
Parts Information
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome
Wheel Staining/Pitting/Corrosion > Page 8352
*This product is currently available from 3M. To obtain information for your local retail location
please call 3M at 1-888-364-3577.
**This product is currently available from Meguiars (Canada). To obtain information for your local
retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com.
^ This product is currently available from Tri-Peek International. To obtain information for your local
retail location please call Tri-Peek at
1-877-615-4272 or at www.tripeek.com.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels
Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels
INFORMATION
Bulletin No.: 99-08-51-007E
Date: March 17, 2011
Subject: Refinishing Aluminum Wheels
Models:
2012 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add additional model years. Please discard Corporate
Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories).
This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not
endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic
refinishing of the wheel's coatings, using recommended procedures, is allowed.
Evaluating Damage
In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion,
scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be
sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the
wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been
refinished by an outside company must be returned to the same vehicle. The Dealer must record
the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to
Refinisher's Responsibility - Outside Company later in this bulletin.
Aluminum Wheel Refinishing Recommendations
- Chrome-plated aluminum wheels Re-plating these wheels is not recommended.
- Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the
clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be
performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later
in this bulletin.
- Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat
procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original
coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum
Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel.
- Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them.
In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is
possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel
should be resurfaced by using a sanding process rather than a machining process. This allows the
least amount of material to be removed.
Important Do not use any re-machining process that removes aluminum. This could affect the
dimensions and function of the wheel.
Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will
better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM
recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle
SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using
any of the painting options, it is recommended that all four wheels be refinished in order to maintain
color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures
and product recommendations.
Refinisher's Responsibility - Outside Company
Important Some outside companies are offering wheel refinishing services. Such refinished wheels
will be permanently marked by the refinisher and are warranted by the refinisher. Any process that
re-machines or otherwise re-manufactures the wheel should not be used.
A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent.
Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is
allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to
assure that the same wheel is returned. A plastic media blast may be used for clean up of the
wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed.
Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed.
Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel
mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel
and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the
new vehicle warranty, whichever is
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longer.
Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact
surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut
torque.
When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to
reduce the chance of future cosmetic damage.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions
Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions
INFORMATION
Bulletin No.: 06-03-10-010A
Date: June 09, 2010
Subject: Information on Proper Wheel Changing Procedures and Cautions
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab
9-7X 2005-2009 Saturn Vehicles
Attention:
Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel
Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and
reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel
installation. Always refer to SI for wheel lug nut torque specifications and complete jacking
instructions for safe wheel changing.
Supercede: This bulletin is being revised to include the 2011 model year and update the available
special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension).
Frequency of Wheel Changes - Marketplace Driven
Just a few years ago, the increasing longevity of tires along with greater resistance to punctures
had greatly reduced the number of times wheels were removed to basically required tire rotation
intervals. Today with the booming business in accessory wheels/special application tires (such as
winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more
than ever. With this increased activity, it opens up more of a chance for error on the part of the
technician. This bulletin will review a few of the common concerns and mistakes to make yourself
aware of.
Proper Servicing Starts With the Right Tools
The following tools have been made available to assist in proper wheel and tire removal and
installation.
- J 41013 Rotor Resurfacing Kit (or equivalent)
- J 42450-A Wheel Hub Resurfacing Kit (or equivalent)
Corroded Surfaces
One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle.
Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened
wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed
away from water splash. This action may result in clearance at the mating surface of the wheel and
an under-torqued condition.
Caution
Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or
brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting
surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is
moving, possibly resulting in a loss of control or personal injury.
Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If
corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding
pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating
surface.
The J 41013 (or equivalent) can be used to clean the following surfaces:
- The hub mounting surface
- The brake rotor mounting surface
- The wheel mounting surface
Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub.
Lubricants, Grease and Fluids
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Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 8362
Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in
removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to
installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper
readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY.
Notice
Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or
drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to
clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light
coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel
pilot hole to prevent wheel seizure to the axle or bearing hub.
Wheel Stud and Lug Nut Damage
Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse.
You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not
retain properly, yet give the impression of fully tightening. Always inspect and replace any
component suspected of damage.
Tip
Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged
BEFORE tightening the nut.
Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side
of the tire is pointing in the direction of forward rotation.
Wheel Nut Tightening and Torque
Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid
additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown
for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in
order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off
center resulting in vibration.
The Most Important Service You Provide
While the above information is well known, and wheel removal so common, technicians run the risk
of becoming complacent on this very important
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Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 8363
service operation. A simple distraction or time constraint that rushes the job may result in personal
injury if the greatest of care is not exercised. Make it a habit to double check your work and to
always side with caution when installing wheels.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire
Radial Force Variation (RFV)
Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV)
INFORMATION
Bulletin No.: 00-03-10-006F
Date: May 04, 2010
Subject: Information on Tire Radial Force Variation (RFV)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009
and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION
Supercede: This bulletin is being revised to considerably expand the available information on
Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin
Number 00-03-10-006E (Section 03 - Suspension).
Important
- Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven
a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin
Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires.
- Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel
assemblies for each vehicle.
The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation
measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable
tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force
variation is highway speed shake on smooth roads.
Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out
of round and tire force variation. These three conditions are not necessarily related. All three
conditions must be addressed.
Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle,
two plane dynamic wheel balancers are readily available and can accurately correct any
imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer,
and proper balance weights, are all factors required for a quality balance. However, a perfectly
balanced tire/wheel assembly can still be "oval shaped" and cause a vibration.
Before balancing, perform the following procedures.
Tire and Wheel Diagnosis
1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are
centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while
shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick.
3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and
correct as necessary:
- Missing balance weights
- Bent rim flange
- Irregular tire wear
- Incomplete bead seating
- Tire irregularities (including pressure settings)
- Mud/ice build-up in wheel
- Stones in the tire tread
- Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to
diagnosing a smooth road shake condition.
4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a
sufficient distance on a known, smooth road
surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes
are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section
of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration
as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order
(one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high
enough in frequency that most humans can start to hear them at highway speeds, but are too high
to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment.
If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a
throbbing), chances are good that the vehicle could have driveline vibration. This type
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire
Radial Force Variation (RFV) > Page 8368
of vibration is normally felt more in the "seat of the pants" than the steering wheel.
5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found
at the end of this bulletin. This should be done
after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to
eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency
is prior to vehicle service and documents the amount of improvement occurring as the result of the
various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required.
A copy of the completed worksheet must be saved with the R.O. and a copy included with any
parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically
indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number
08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if
this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away
and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration
may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if
vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire
flat-spotting can be ruled out as the cause for vibration.
6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle
being parked for long periods of time and that the
nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information
on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment
Tires.
7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel
assembly on a known, calibrated, off-car dynamic
balancer.Make sure the mounting surface of the wheel and the surface of the balancer are
absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and
always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is
not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim
flange, remove all balance weights and rebalance to as close to zero as possible. If you can see
the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the
wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First
order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or
hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough,
it can be seen.
If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and
force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700
can address both (it is also a wheel balancer).
Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will
produce in one revolution under a constant load. Radial force variation is what the vehicle feels
because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not
under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel
assembly runout be within specification.
Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures
radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV
measurement at this point. To isolate the wheel, its runout must be measured. This can be easily
done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout
specification, the tire's RFV can then be addressed.
After measuring the tire/wheel assembly under load, and the wheel alone, the machine then
calculates (predicts) the radial force variation of the tire. However, because this is a prediction that
can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in
tire production, this type of service equipment should NOT be used to audit new tires. Rather, it
should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel
assembly.
Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of
finding the low point of the wheel (for runout) and the high point of the tire (for radial force
variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly
force variation.
The machine will simplify this process into easy steps. The following assembly radial force variation
numbers should be used as a guide:
When measuring RFV and match mounting tires perform the following steps.
Measuring Wheel Runout and Assembly Radial Force Variation
Important The completed worksheet at the end of this bulletin must be attached to the hard copy of
the repair order.
- Measure radial force variation and radial runout.
- If a road force/balancing machine is used, record the radial force variation (RFV) on the
worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the
front left corner. If the machine is not available and the EVA data suggests there is an issue, swap
the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem
still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those
tires onto the subject vehicle.
- If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the
worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040
in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive
customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to
have the lowest runout assembly to the front left corner. If the machine is not available and the
EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the
back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do
not exhibit the same frequency and swap those tires
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire
Radial Force Variation (RFV) > Page 8369
onto the subject vehicle.
- After match mounting, the tire/wheel assembly must be rebalanced.
If match mounting tires to in-spec wheels produces assembly values higher than these, tire
replacement may be necessary. Replacing tires at lower values will probably mean good tires are
being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect
force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring.
Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to
measuring.
Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are
more sensitive, and may require lower levels. Also, there are other tire parameters that equipment
such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be
contacted for further instructions.
Important
- When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's
center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are
secondary. Usually a back cone method to the machine should be used. For added accuracy and
repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This
system is offered by all balancer manufacturers in GM's dealer program.
- Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT
recommended, and may void the tire warranty. However, tires may have been ground by the tire
company as part of their tire manufacturing process. This is a legitimate procedure.
Steering Wheel Shake Worksheet
When diagnosing vibration concerns, use the following worksheet in conjunction with the
appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI.
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire
Radial Force Variation (RFV) > Page 8370
Refer to the appropriate section of SI for specifications and repair procedures that are related to the
vibration concern.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low
Tire/Leaking Cast Aluminum Wheels
Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels
TECHNICAL
Bulletin No.: 05-03-10-003F
Date: April 27, 2010
Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels
Supercede: This bulletin is being revised to update the model years and the bulletin reference
information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension).
Condition
Some customers may comment on a low tire pressure condition.
Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel.
Cause
Porosity in the cast aluminum wheel may be the cause.
Notice
This bulletin specifically addresses issues related to the wheel casting that may result in an air
leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin
Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light
Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat).
Correction
1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service
procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the
tire/wheel assembly in a water bath, or use a spray bottle with soap
and water to locate the specific leak location.
Important
- If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim),
the wheel should be replaced.
- If two or more leaks are located on one wheel, the wheel should be replaced.
3. If air bubbles are observed, mark the location.
- If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks.
- If the leak is located on the aluminum wheel area, continue with the next step.
4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the
wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove
the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the
INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose
cleaner, such as 3M(R) General Purpose
Adhesive Cleaner, P/N 08984, or equivalent.
8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use
88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry.
Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging
the repair area may result in an air leak.
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Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low
Tire/Leaking Cast Aluminum Wheels > Page 8375
10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire
Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on
the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and
inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the
tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire
and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty
one tube of adhesive/sealant per wheel repair.
For vehicles repaired under warranty, use:
One leak repair per wheel.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire
Slowly Goes Flat/Warning Light ON
Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON
TECHNICAL
Bulletin No.: 08-03-10-006C
Date: April 27, 2010
Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated,
Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat)
Models:
2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 08-03-10-006B (Section 03 - Suspension).
Condition
Some customers may comment on a tire that slowly loses air pressure over a period of days or
weeks.
Cause
Abrasive elements in the environment may intrude between the tire and wheel at the bead seat.
There is always some relative motion between the tire and wheel (when the vehicle is driven) and
this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear
continues, there may also be intrusion at the tire/wheel interface by corrosive media from the
environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may
appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be
visible until the tire is dismounted from the wheel.
Notice
This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in
an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please
refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum
Wheels (Repair with Adhesive Sealant)
Correction
In most cases, this type of air loss can be corrected by following the procedure below.
Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to
repair the wheel with the procedure below.
Notice
The repair is no longer advised or applicable for chromed aluminum wheels.
1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and
Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to
be around the bead seat of the wheel, dismount the tire to examine
the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat
Corrosion
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Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire
Slowly Goes Flat/Warning Light ON > Page 8380
Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel
flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for
additional information on possible wheel porosity issues.
3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a
rough or uneven surface that is difficult for the tire to
maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel
that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion
4. If corrosion is found on the wheel bead seat, measure the affected area as shown below.
- For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of
repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
- For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area
of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the
corrosion and any flaking paint. You should
remove the corrosion back far enough until you reach material that is stable and firmly bonded to
the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges
that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired
surface.
Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be
visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not
visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend
to the visible surfaces on the FACE of the wheel, that wheel must be replaced.
Important Remove ONLY the material required to eliminate the corrosion from the bead seating
surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as
smooth and level as possible.
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire
Slowly Goes Flat/Warning Light ON > Page 8381
Acceptably Prepared (Cleaned-Up) Wheel Surface
6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially
available tire sealant such as Patch Brand Bead
Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will
permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this
sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat
7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel
Removal and Installation in SI.
Parts Information
Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at
www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire
Slowly Goes Flat/Warning Light ON > Page 8382
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion
INFORMATION
Bulletin No.: 00-03-10-002F
Date: April 21, 2011
Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum
Wheels
Models:
2012 and Prior GM Cars and Trucks
Supercede: This bulletin is being revised to update model years, suggest additional restorative
products and add additional corrosion information. Please discard Corporate Bulletin Number
00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the
customer.
What is Chemical Staining of Chrome Wheels? Figure 1
Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an
example). These stains are frequently milky, black, or greenish in appearance. They result from
using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient
to clean wheels.
If the customer insists on using a wheel cleaner they should only use one that specifically states
that it is safe for chromed wheels and does not contain anything in the following list. (Dealers
should also survey any products they use during prep or normal cleaning of stock units for these
chemicals.)
- Ammonium Bifluoride (fluoride source for dissolution of chrome)
- Hydrofluoric Acid (directly dissolves chrome)
- Hydrochloric Acid (directly dissolves chrome)
- Sodium Dodecylbenzenesulfonic Acid
- Sulfamic Acid
- Phosphoric Acid
- Hydroxyacetic Acid
Notice
Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most
customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal.
Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the
paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car
warranty. Soap and water applied with a soft brush is usually all that is required to clean the
calipers.
Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean,
clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts,
lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to
the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the
damage around and under the wheel weight where the cleaner was incompletely flushed away.
Notice
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 8388
Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome
wheels (or any wheels).
If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be
avoided.
For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and
Instructions below.
Warranty of Stained Chrome Wheels
Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome
wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were
returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be
charged back to the dealership. To assist the customer, refer to Customer Assistance and
Instructions below.
Pitting or Spotted Appearance of Chrome Wheels Figure 2
A second type or staining or finish disturbance may result from road chemicals, such as calcium
chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to
Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be
uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels
should be washed with mild soap and water and thoroughly rinsed as soon as conveniently
possible.
Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can
also stain chrome wheels. The staining will look like small pitting. This staining will usually be on
the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward
direction while being splashed by the road chemical. If a vehicle must be operated under such
conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed
as soon as conveniently possible.
Warranty of Pitted or Spotted Chrome Wheels
Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time.
Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish
and may cause damage if the wheels are not kept clean.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean if they are operating the vehicle in an area that
applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior
approval by the District Manager - Customer Care and Service Process (DM-CCSP).
"Stardust" Corrosion of Chrome Wheels Figure 3
A third type of finish disturbance results from prolonged exposure to brake dust and resultant
penetration of brake dust through the chrome. As brakes are applied hot particles of brake material
are thrown off and tend to be forced through the leading edge of the wheel spoke windows by
airflow. These
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 8389
hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed
to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the
chrome leaving a pit or small blister in the chrome.
Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and
Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up
or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars
Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be
waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax
#M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake
dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may
be used. It will clean and shine the chrome and leave behind a wax coating that may help protect
the finish.
Warranty of Stardust Corroded Chrome Wheels
Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be
replaced one time.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust
build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care
and Service Process (DM-CCSP).
Customer Assistance and Instructions
GM has looked for ways customers may improve the appearance of wheels damaged by acidic
cleaners. The following product and procedure has been found to dramatically improve the
appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the
following:
Notice
THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN
EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE
APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL
REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED
INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER,
EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS
EXACTLY.
1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce
wheel staining. Flood all areas of the wheel with water
to rinse.
2. Dry the wheels completely.
Notice Begin with a small section of the wheel and with light pressure buff off polish and examine
results. ONLY apply and rub with sufficient force and time to remove enough staining that you are
satisfied with the results. Some wheels may be stained to the extent that you may only achieve a
50% improvement while others may be able to be restored to the original lustre. IN ALL CASES,
only apply until the results are satisfactory.
3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the
polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the
towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If
continued applications fail to improve the appearance
further discontinue use.
This procedure will improve the appearance of the wheels and may, with repeated applications,
restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above
procedure may marginally improve the condition but will not restore the finish or remove the pitting.
In this type of staining the wheel finish has actually been removed in spots and no manner of
cleaning will restore the finish.
†*We believe this source and their products to be reliable. There may be additional manufacturers
of such products/materials. General Motors does not endorse, indicate any preference for or
assume any responsibility for the products or material from this firm or for any such items that may
be available from other sources.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 8390
*This product is currently available from 3M. To obtain information for your local retail location
please call 3M at 1-888-364-3577.
**This product is currently available from Meguiars (Canada). To obtain information for your local
retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com.
^ This product is currently available from Tri-Peek International. To obtain information for your local
retail location please call Tri-Peek at
1-877-615-4272 or at www.tripeek.com.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels
Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels
INFORMATION
Bulletin No.: 99-08-51-007E
Date: March 17, 2011
Subject: Refinishing Aluminum Wheels
Models:
2012 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add additional model years. Please discard Corporate
Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories).
This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not
endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic
refinishing of the wheel's coatings, using recommended procedures, is allowed.
Evaluating Damage
In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion,
scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be
sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the
wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been
refinished by an outside company must be returned to the same vehicle. The Dealer must record
the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to
Refinisher's Responsibility - Outside Company later in this bulletin.
Aluminum Wheel Refinishing Recommendations
- Chrome-plated aluminum wheels Re-plating these wheels is not recommended.
- Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the
clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be
performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later
in this bulletin.
- Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat
procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original
coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum
Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel.
- Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them.
In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is
possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel
should be resurfaced by using a sanding process rather than a machining process. This allows the
least amount of material to be removed.
Important Do not use any re-machining process that removes aluminum. This could affect the
dimensions and function of the wheel.
Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will
better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM
recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle
SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using
any of the painting options, it is recommended that all four wheels be refinished in order to maintain
color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures
and product recommendations.
Refinisher's Responsibility - Outside Company
Important Some outside companies are offering wheel refinishing services. Such refinished wheels
will be permanently marked by the refinisher and are warranted by the refinisher. Any process that
re-machines or otherwise re-manufactures the wheel should not be used.
A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent.
Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is
allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to
assure that the same wheel is returned. A plastic media blast may be used for clean up of the
wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed.
Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed.
Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel
mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel
and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the
new vehicle warranty, whichever is
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 8395
longer.
Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact
surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut
torque.
When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to
reduce the chance of future cosmetic damage.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions
Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions
INFORMATION
Bulletin No.: 06-03-10-010A
Date: June 09, 2010
Subject: Information on Proper Wheel Changing Procedures and Cautions
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab
9-7X 2005-2009 Saturn Vehicles
Attention:
Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel
Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and
reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel
installation. Always refer to SI for wheel lug nut torque specifications and complete jacking
instructions for safe wheel changing.
Supercede: This bulletin is being revised to include the 2011 model year and update the available
special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension).
Frequency of Wheel Changes - Marketplace Driven
Just a few years ago, the increasing longevity of tires along with greater resistance to punctures
had greatly reduced the number of times wheels were removed to basically required tire rotation
intervals. Today with the booming business in accessory wheels/special application tires (such as
winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more
than ever. With this increased activity, it opens up more of a chance for error on the part of the
technician. This bulletin will review a few of the common concerns and mistakes to make yourself
aware of.
Proper Servicing Starts With the Right Tools
The following tools have been made available to assist in proper wheel and tire removal and
installation.
- J 41013 Rotor Resurfacing Kit (or equivalent)
- J 42450-A Wheel Hub Resurfacing Kit (or equivalent)
Corroded Surfaces
One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle.
Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened
wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed
away from water splash. This action may result in clearance at the mating surface of the wheel and
an under-torqued condition.
Caution
Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or
brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting
surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is
moving, possibly resulting in a loss of control or personal injury.
Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If
corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding
pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating
surface.
The J 41013 (or equivalent) can be used to clean the following surfaces:
- The hub mounting surface
- The brake rotor mounting surface
- The wheel mounting surface
Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub.
Lubricants, Grease and Fluids
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 8400
Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in
removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to
installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper
readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY.
Notice
Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or
drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to
clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light
coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel
pilot hole to prevent wheel seizure to the axle or bearing hub.
Wheel Stud and Lug Nut Damage
Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse.
You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not
retain properly, yet give the impression of fully tightening. Always inspect and replace any
component suspected of damage.
Tip
Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged
BEFORE tightening the nut.
Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side
of the tire is pointing in the direction of forward rotation.
Wheel Nut Tightening and Torque
Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid
additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown
for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in
order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off
center resulting in vibration.
The Most Important Service You Provide
While the above information is well known, and wheel removal so common, technicians run the risk
of becoming complacent on this very important
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 8401
service operation. A simple distraction or time constraint that rushes the job may result in personal
injury if the greatest of care is not exercised. Make it a habit to double check your work and to
always side with caution when installing wheels.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > Page 8402
Wheels: Description and Operation
Replacement Wheels Description
Replace the wheel if any of the following conditions exist:
* The wheel exhibits excessive runout.
* The wheel is bent.
* The wheel is cracked.
* The wheel is severely rusted.
* The wheel is severely corroded.
Note: Air leaks caused by porosity on aluminum wheels are repairable.
* The wheel leaks air.
Warning
If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install
only new GM original equipment parts. Installation of used parts or non-GM original equipment
parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of
vehicle control resulting in personal injury.
Caution: The use of non-GM original equipment wheels may cause:
* Damage to the wheel bearing, the wheel fasteners and the wheel
* Tire damage caused by the modified clearance to the adjacent vehicle components
* Adverse vehicle steering stability caused by the modified scrub radius
* Damage to the vehicle caused by the modified ground clearance
* Speedometer and odometer inaccuracy
Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of
the following conditions exist:
* The wheel has elongated bolt holes.
* The wheel/nuts, or bolts if applicable, loosen repeatedly.
Steel wheel identification is stamped into the wheel near the valve stem.
Aluminum wheel identification is cast into the inboard side of the wheel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service
and Repair > Aluminum Wheel Porosity Repair
Wheels: Service and Repair Aluminum Wheel Porosity Repair
Aluminum Wheel Porosity Repair
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and
Installation (See: Service and Repair). 3. Inflate the tire to the manufacturer specified pressure as
stated on the tire. 4. Submerge the tire/wheel into a water bath in order to locate the leak. 5.
Inscribe a mark on the wheel in order to indicate the leak areas. 6. Inscribe a mark on the tire at the
valve stem in order to indicate the orientation of the tire to the wheel. 7. Remove the tire from the
wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and
Replacement).
Important: Do not damage the exterior surface of the wheel.
8. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 9. Use
general purpose cleaner such as 3M(R), P/N 08984 or equivalent, to clean the leak area.
10. Apply 3 mm (0.12 in) thick layer of adhesive/sealant, GM P/N 1052366 or equivalent, to the
leak area. 11. Allow for the adhesive/sealant to dry. 12. Align the inscribed mark on the tire with the
valve stem on the wheel. 13. Install the tire to the wheel. Refer to Tire Dismounting and Mounting
(See: Tires/Service and Repair/Removal and Replacement). 14. Inflate the tire to the manufacturer
specified pressure as stated on the tire. 15. Submerge the tire/wheel into a water bath in order
ensure the leak is sealed. 16. Balance the tire and wheel. Refer to Tire and Wheel Assembly
Balancing - Off Vehicle (See: Testing and Inspection/Symptom Related
Diagnostic Procedures/Vibration Diagnosis and Correction/Repair Instructions/Tire and Wheel
Assembly Balancing - Off Vehicle).
17. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and
Repair). 18. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service
and Repair > Aluminum Wheel Porosity Repair > Page 8405
Wheels: Service and Repair Aluminum Wheel Refinishing
Aluminum Wheel Refinishing
Finish Damage Evaluation Procedure
Note: *
If the wheels are chrome-plated, do not re-plate or refinish the wheels.
* If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize
a refinisher that meets manufacturer guidelines.
1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car
wash facilities. 2. Inspect the wheels for the following conditions:
* Corrosion
* Scrapes
* Gouges
3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for
cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim
flange is bent, discard the wheel.
Refinishing Procedure
Warning
To avoid serious personal injury when applying any two part component paint system, follow the
specific precautions provided by the paint manufacturer. Failure to follow these precautions may
cause lung irritation and allergic respiratory reaction.
1. Remove the tire and wheel assembly from the vehicle. Refer to Tire and Wheel Removal and
Installation (See: Service and Repair). 2. Remove the balance weights from the wheel. 3. Remove
the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and
Repair/Removal and Replacement). 4. Use a suitable cleaner in order to remove the following
contaminants from the wheel:
* Lubricants
* Wax
* Dirt
Note: *
Do not re-machine the wheel.
* Do not use chemicals in order to strip the paint from the wheel.
5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a
machined aluminum finish, spin the wheel and use sand paper in order to restore the circular
machined appearance.
Note: The wheel mounting surface and the wheel nut contact surface must remain free of paint.
7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint
manufacturer's instructions for painting the wheel. 9. Unmask the wheel.
10. Install a new valve stem.
Note: Use new coated balance weights in order to balance the wheel.
11. Install the tire to the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and
Repair/Removal and Replacement). 12. Use a suitable cleaner in order to remove the following
contaminants from the wheel mounting surface:
* Corrosion
* Overspray
* Dirt
13. Install the tire and wheel assembly to the vehicle. Refer to Tire and Wheel Removal and
Installation (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Testing and Inspection
Wheel Bearing: Testing and Inspection
Wheel Bearings Diagnosis
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Testing and Inspection > Page 8409
Wheel Bearing: Service and Repair
Front Wheel Bearing and Hub Replacement
Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction
Control/Service Precautions/Technician Safety Information/Brake Dust Warning ).
Warning: Refer to ABS Component Handling Warning (See: Brakes and Traction Control/Service
Precautions/Technician Safety Information/ABS Component Handling Warning).
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and
Repair). 2. Remove the front brake caliper. Refer to Brake Caliper Replacement (See: Brakes and
Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Brake Caliper Replacement).
3. Remove the speed sensor electrical connector and the mounting bracket. Refer to Front Wheel
Speed Sensor Replacement (See: Brakes and
Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and
Repair/Front Wheel Speed Sensor Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Testing and Inspection > Page 8410
4. To ensure the ease of removal, bundle speed sensor wiring harness so not to have it entangled
in any of the suspension components.
Note: The following service procedure applies to those vehicles that are equipped with 4 wheel
drive ONLY.
5. Remove the steering knuckle assembly. Refer to Steering Knuckle Replacement (See:
Steering/Front Steering Knuckle/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Testing and Inspection > Page 8411
6. Remove the mounting bolts for the wheel bearing/hub, brake rotor assembly.
7. Remove the wheel bearing/hub, brake rotor assembly from the steering knuckle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Testing and Inspection > Page 8412
Note: Perform the following service procedure with the brake rotor on a flat surface.
8. Remove the mounting bolt from the wheel bearing/hub, to the brake rotor.
Note: The splash shield will come off the steering knuckle when the wheel bearing/hub, brake rotor
is removed.
9. Remove the wheel bearing/hub from the brake rotor.
10. Clean the contact area between the wheel bearing/hub and the brake rotor.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Testing and Inspection > Page 8413
1. Position the wheel bearing/hub assembly on the brake rotor. 2. Install the mounting bolts from
the wheel bearing/hub assembly to the brake rotor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: The following service procedure is to be performed on a flat surface and to ensure that the
brake rotor is securely attached to the hub assembly prior to the final torquing procedure. DO NOT
use air tools of any type for this procedure.
3. Tighten the bolts in crisscross pattern. Tighten the mounting bolts to 20 Nm (15 lb ft). 4. Install
the backing plate to the wheel bearing/hub, brake rotor assembly.
Note: The following service procedure applies to those vehicles that are equipped with 4 wheel
drive ONLY.
5. Install the steering knuckle assembly. Refer to Steering Knuckle Replacement (See:
Steering/Front Steering Knuckle/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Testing and Inspection > Page 8414
6. Install the wheel bearing/hub, brake rotor assembly in the steering knuckle.
Note: When performing the following service procedure, DO NOT use air tools of any type to torque
the brake rotor to hub bolts.
7. Install the wheel bearing/hub, brake rotor mounting bolts and tighten to 125 Nm (92 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Testing and Inspection > Page 8415
8. Install the brake caliper mounting bracket to the steering knuckle.
9. Install the mounting bolts for the brake caliper mounting bracket and tighten to 175 Nm (129 lb
ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Testing and Inspection > Page 8416
10. Position a large screwdriver or pry bar in the cooling fins of the brake rotor and the brake
caliper mounting bracket.
Note: The following service procedure is to ensure that the brake rotor is seated properly on the
wheel bearing/hub assembly.
11. Tighten the mounting bolts for the brake rotor in sequence.
12. Using a torque wrench, tighten the mounting bolts to 110 Nm (81 lb ft). 13. Install the speed
sensor mounting bracket and re-connect the electrical connector. Refer to Front Wheel Speed
Sensor Replacement (See: Brakes
and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and
Repair/Front Wheel Speed Sensor Replacement).
14. Check for hub/rotor/bearing LRO specifications. Refer to Disc Brake Component Specifications
(See: Brakes and Traction Control/Disc Brake
System/Specifications/Disc Brake Component Specifications).
15. Install the brake caliper assembly. Refer to Brake Caliper Replacement (See: Brakes and
Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Brake Caliper Replacement).
16. Install the wheel speed sensor to the body. 17. Lower the vehicle. Refer to Lifting and Jacking
the Vehicle (See: Vehicle Lifting/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component
Information > Specifications
Axle Nut: Specifications
Drive Shaft Nut ....................................................................................................................................
.................................................... 260 Nm (191 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information
> Specifications
Wheel Fastener: Specifications
Wheel Nuts...........................................................................................................................................
.......................................................140 Nm (103 lb ft)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information
> Specifications > Page 8424
Wheel Fastener: Description and Operation
Metric Wheel Nuts and Bolts Description
Metric wheel/nuts and bolts are identified in the following way:
* The wheel/nut has the word Metric stamped on the face.
* The letter M is stamped on the end of the wheel bolt.
The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x
1.5.
* M = Metric
* 12 = Diameter in millimeters
* 1.5 = Millimeters gap per thread
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information
> Service and Repair > Front Suspension
Wheel Fastener: Service and Repair Front Suspension
Wheel Stud Replacement
Tools Required
J 43631 Ball Joint Remover
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and
Installation (See: Service and Repair). 3. Remove the brake rotor. Refer to Brake Rotor
Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and
Repair/Removal and Replacement/Brake Rotor Replacement).
4. Remove the wheel stud from the hub flange using the J 43631 . 5. Remove the wheel stud from
the hub flange.
Installation Procedure
1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the
new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub
flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the
wheel nut. 6. Remove the washers.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information
> Service and Repair > Front Suspension > Page 8427
7. Install the brake rotor. Refer to Brake Rotor Replacement (See: Brakes and Traction
Control/Disc Brake System/Brake Rotor/Disc/Service and
Repair/Removal and Replacement/Brake Rotor Replacement).
8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and
Repair). 9. Remove the safety stands.
10. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information
> Service and Repair > Front Suspension > Page 8428
Wheel Fastener: Service and Repair Rear Suspension
Wheel Stud Replacement
Tools Required
J 43631 Ball Joint Separator
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle
Lifting/Service and Repair). 2. Remove the rear brake drum. Refer to Brake Drum Replacement
(See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service
and Repair/Removal and Replacement).
3. Using the J 43631 , remove the wheel stud.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information
> Service and Repair > Front Suspension > Page 8429
1. Position the wheel stud in the axle flange. 2. Install the 4 washers and the lug nut to the stud. 3.
Tighten the lug nut until the stud fully seats. 4. Remove the lug nut and the washers.
5. Install the rear brake drum. Refer to Brake Drum Replacement (See: Brakes and Traction
Control/Drum Brake System/Brake Drum/Service and
Repair/Removal and Replacement).
6. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Locations > Instrument Panel/Center Console Component Views
Air Door Actuator / Motor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Behind the I/P Components
1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation
Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Locations > Instrument Panel/Center Console Component Views > Page 8436
Air Door Actuator / Motor: Locations Harness Routing Views
Harness Routing Views
HVAC Harness Routing
1 - Evaporator Temperature Sensor (C60) 2 - X203 (I/P Harness to the HVAC Harness) 3 Recirculation Actuator (C60) 4 - Blower Motor 5 - J202 6 - Blower Motor Resistor Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Locations > Page 8437
Air Door Actuator / Motor: Diagrams
Component Connector End Views
Recirculation Actuator (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Mode Control Cam Replacement
Air Door Actuator / Motor: Service and Repair Mode Control Cam Replacement
Mode Control Cam Replacement
Removal Procedure
Note: The mode cam can be accessed from the driver side floor near the accelerator peddle.
1. Remove the mode control cable (4) from the retaining clip (3).
2. Remove the mode control cable (4) from the mode cam (2). 3. Remove the screw (1) from the
mode cam. 4. Remove the mode cam.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Mode Control Cam Replacement > Page 8440
1. Install the mode cable (4). 2. Make certain that the cable is properly seated in the notch in the
HVAC module.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the mode cam screw. Tighten the screw to 2 Nm (18 lb in). 4. Install the mode control
cable (4) to the mode cam (2). 5. Install the mode control cable (4) to the retaining clip (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Mode Control Cam Replacement > Page 8441
Air Door Actuator / Motor: Service and Repair Recirculation Actuator Replacement
Recirculation Actuator Replacement
Removal Procedure
1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See:
Housing Assembly HVAC/Service and Repair).
2. Remove the recirculation actuator screws. 3. Remove the electrical connector (3) from the
recirculation actuator (2). 4. Remove the recirculation actuator.
Installation Procedure
1. Install the recirculation actuator (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Mode Control Cam Replacement > Page 8442
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the screws to the recirculation actuator. Tighten the screws to 1.9 Nm (17 lb ft). 3.
Connect the electrical connector (3) to the recirculation actuator (2). 4. Install the HVAC module
assembly. Refer to HVAC Module Assembly Replacement (See: Housing Assembly HVAC/Service
and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component
Information > Service and Repair > Mode Control Cable Replacement
Air Door Cable: Service and Repair Mode Control Cable Replacement
Mode Control Cable Replacement
Removal Procedure
1. Remove the radio. Refer to Radio Replacement (See: Accessories and Optional
Equipment/Radio, Stereo, and Compact
Disc/Radio/Stereo/Service and Repair/Radio Replacement).
2. Remove the mounting screws from the HVAC control assembly.
3. Remove the mode cable (4) from the retaining clip (3) and remove the mode cable. 4. Remove
the mode cable (4) from the mode control cam.
5. Remove the mode cable (3) from the HVAC control assembly (6). 6. Remove the mode control
cable.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component
Information > Service and Repair > Mode Control Cable Replacement > Page 8447
Installation Procedure
1. Install the mode cable (3).
Make certain that the cable is properly seated in the notches in the HVAC control assembly (6).
2. Install the mode cable (3) to the HVAC control assembly (6). 3. Install the mode cable to the
retaining clip.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the mounting screws to the HVAC control assembly. Tighten the screws to 1.9 Nm (17 lb
in). 5. Install the radio. Refer to Radio Replacement (See: Accessories and Optional
Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service
and Repair/Radio Replacement).
6. Install the mode cable (4) to the mode control cam (2). 7. Install the mode cable (4) to the
retaining clip (3). 8. Install the radio. Refer to Radio Replacement (See: Accessories and Optional
Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component
Information > Service and Repair > Mode Control Cable Replacement > Page 8448
and Repair/Radio Replacement).
9. Install the HVAC control assembly. Refer to Heater and Air Conditioning Control Replacement
(See: Control Assembly/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component
Information > Service and Repair > Mode Control Cable Replacement > Page 8449
Air Door Cable: Service and Repair Temperature Control Cable Replacement
Temperature Control Cable Replacement
Removal Procedure
1. Remove the accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement
(See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
2. Remove the mounting screws from the HVAC control assembly.
3. Remove the temperature cable (4) from the retaining clip and remove the temperature cable. 4.
Remove the temperature cable (4) from the temperature control cam (5). 5. Fully open the I/P
storage compartment.
6. Remove the temperature control cable from the retaining clip.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component
Information > Service and Repair > Mode Control Cable Replacement > Page 8450
7. Remove the temperature control cable (9) from the temperature actuator cam (10). 8. Remove
the temperature control cable.
Installation Procedure
1. Install the temperature cable (4). 2. Install the temperature control cable (9) to the temperature
actuator cam (10). 3. Install the temperature cable to the retaining clip.
4. Install the temperature cable (4) to the temperature control cam (5). 5. Install the temperature
cable (4) to the retaining clip.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the mounting screws to the HVAC control assembly. Tighten the screws to 1.9 Nm (17 lb
in). 7. Install the accessory trim plate. Refer to Instrument Panel Accessory Trim Plate
Replacement (See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair
Air Duct: Service and Repair
Air Distributor Duct Replacement
Removal Procedure
1. Remove the instrument panel (I/P) assembly. Refer to Instrument Panel Assembly Replacement
(See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
2. Remove the air distributor duct (1) from the instrument panel.
Installation Procedure
1. Install the air distributor duct (1) to the instrument panel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the retaining screws to the air distributor duct. Tighten the screws to 1.9 Nm (17 lb in). 3.
Install the I/P assembly. Refer to Instrument Panel Assembly Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Rear Floor Air Outlet Replacement
Air Register: Service and Repair Rear Floor Air Outlet Replacement
Rear Floor Air Outlet Replacement
Removal Procedure
1. Remove the floor console. Refer to Console Replacement (Large w/Manual or Auto
Transmission) (See: Body and Frame/Interior Moulding /
Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See:
Body and Frame/Interior Moulding / Trim/Console/Service and Repair).
2. Roll the carpeting back to expose the rear floor air ducts.
3. Remove the rear floor ducts from the floor studs.
4. Remove the rear floor duct.
Installation Procedure
1. Install the rear floor air duct.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Rear Floor Air Outlet Replacement > Page 8458
2. Install the rear floor ducts from the floor studs. 3. Position the carpeting back into place. 4. Install
the floor console. Refer to Console Replacement (Large w/Manual or Auto Transmission) (See:
Body and Frame/Interior Moulding /
Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See:
Body and Frame/Interior Moulding / Trim/Console/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Rear Floor Air Outlet Replacement > Page 8459
Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side
Instrument Panel Outer Air Outlet Replacement - Left Side
Removal Procedure
1. Using a flat-bladed plastic tool, carefully release the 4 tabs (1) retaining the air outlet assembly
to the instrument panel (I/P).
2. Remove the air outlet assembly from the I/P
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Rear Floor Air Outlet Replacement > Page 8460
3. If replacing the vent assembly or the bezel, separate the bezel from the vent assembly by
carefully releasing the 4 retaining tabs.
Installation Procedure
1. If replacing the vent assembly or the bezel, install the bezel to the vent assembly by seating the
4 retaining tabs.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Rear Floor Air Outlet Replacement > Page 8461
2. Install the air outlet assembly to the I/P ensuring the retaining tabs are fully seated.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Rear Floor Air Outlet Replacement > Page 8462
Air Register: Service and Repair Instrument Panel Center Air Outlet Replacement
Instrument Panel Center Air Outlet Replacement
Removal Procedure
1. Remove the instrument panel (I/P) accessory trim plate. Refer to Instrument Panel Accessory
Trim Plate Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair).
2. Remove the right air outlet assembly from the trim plate. 3. Remove the left air outlet assembly
from the trim plate.
Installation Procedure
1. Install the left air outlet assembly to the trim plate. 2. Install the right air outlet assembly to the
trim plate.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Rear Floor Air Outlet Replacement > Page 8463
3. Install the accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement
(See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Rear Floor Air Outlet Replacement > Page 8464
Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Right Side
Instrument Panel Outer Air Outlet Replacement - Right Side
Removal Procedure
1. Using a flat-bladed plastic tool, carefully release the 4 tabs (1) retaining the air outlet assembly
to the instrument panel (I/P).
2. Remove the air outlet assembly from the I/P
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Rear Floor Air Outlet Replacement > Page 8465
3. If replacing the vent assembly or the bezel, separate the bezel from the vent assembly by
carefully releasing the 4 retaining tabs.
Installation Procedure
1. If replacing the vent assembly or the bezel, install the bezel to the vent assembly by seating the
4 retaining tabs.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Rear Floor Air Outlet Replacement > Page 8466
2. Install the air outlet assembly to the I/P ensuring the retaining tabs are fully seated.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Customer Interest for Blower Motor: > 06-01-38-001C > Jul > 10 > A/C - Blower Motor Clicking/Chirping/Whirring
Noises
Blower Motor: Customer Interest A/C - Blower Motor Clicking/Chirping/Whirring Noises
TECHNICAL
Bulletin No.: 06-01-38-001C
Date: July 14, 2010
Subject: Excessive Blower Motor Clicking/Chirping/Whirring or Ticking Noise on Low Speed (Install
Blower Motor Sound Insulator Cover)
Models:
2005-2010 Chevrolet Colorado 2005-2010 GMC Canyon
Supercede: This bulletin is being revised to update the model years to 2010. Please discard
Corporate Bulletin Number 06-01-38-001B (Section 01 - HVAC).
Condition
Some customers may comment on excessive or annoying blower motor noise on low fan speed.
Sounds may include ticking, chirping, clicking or whirring noises.
Cause
The blower motor is located within the vehicle under the passenger side lower IP. This location,
while allowing for increased serviceability, does not offer much isolation from blower motor noise.
Correction
To reduce the noise level from the blower motor, install a blower motor sound insulator cover using
the procedure below.
1. Remove the front passenger door sill molding. 2. Remove the front passenger side interior kick
panel molding. 3. Remove the front passenger interior floor courtesy light. 4. Remove the BCM
connector facing the blower motor. 5. Remove the wire retaining metal clip from the BCM harness.
6. Install the molded insulator to the blower motor. Refer to the above illustration. The insulator may
need to be flexed in order to be properly
situated on the motor. When the insulator is properly installed, it will be form fitted to the motor and
the retainer hole in the cover (1) will align with a hole in the back side of the motor body.
7. A stud will align with the second hole in the insulating cover. Refer to location (2) in the above
illustration, which shows the location of the stud
(not visible in photo). Please note the location of the BCM in the photo. This should aid in properly
locating the cover.
8. Use the push-pin to secure the cover in place. 9. Re-route the BCM harness over the newly
installed cover and retain using the metal clip. This should give additional support to the flexible
blower
motor cover.
10. Install the front passenger interior floor courtesy light. 11. Install the front passenger side
interior kick panel molding. 12. Install the front passenger door sill molding.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Customer Interest for Blower Motor: > 06-01-38-001C > Jul > 10 > A/C - Blower Motor Clicking/Chirping/Whirring
Noises > Page 8475
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Blower Motor: > 06-01-38-001C > Jul > 10 > A/C - Blower Motor
Clicking/Chirping/Whirring Noises
Blower Motor: All Technical Service Bulletins A/C - Blower Motor Clicking/Chirping/Whirring Noises
TECHNICAL
Bulletin No.: 06-01-38-001C
Date: July 14, 2010
Subject: Excessive Blower Motor Clicking/Chirping/Whirring or Ticking Noise on Low Speed (Install
Blower Motor Sound Insulator Cover)
Models:
2005-2010 Chevrolet Colorado 2005-2010 GMC Canyon
Supercede: This bulletin is being revised to update the model years to 2010. Please discard
Corporate Bulletin Number 06-01-38-001B (Section 01 - HVAC).
Condition
Some customers may comment on excessive or annoying blower motor noise on low fan speed.
Sounds may include ticking, chirping, clicking or whirring noises.
Cause
The blower motor is located within the vehicle under the passenger side lower IP. This location,
while allowing for increased serviceability, does not offer much isolation from blower motor noise.
Correction
To reduce the noise level from the blower motor, install a blower motor sound insulator cover using
the procedure below.
1. Remove the front passenger door sill molding. 2. Remove the front passenger side interior kick
panel molding. 3. Remove the front passenger interior floor courtesy light. 4. Remove the BCM
connector facing the blower motor. 5. Remove the wire retaining metal clip from the BCM harness.
6. Install the molded insulator to the blower motor. Refer to the above illustration. The insulator may
need to be flexed in order to be properly
situated on the motor. When the insulator is properly installed, it will be form fitted to the motor and
the retainer hole in the cover (1) will align with a hole in the back side of the motor body.
7. A stud will align with the second hole in the insulating cover. Refer to location (2) in the above
illustration, which shows the location of the stud
(not visible in photo). Please note the location of the BCM in the photo. This should aid in properly
locating the cover.
8. Use the push-pin to secure the cover in place. 9. Re-route the BCM harness over the newly
installed cover and retain using the metal clip. This should give additional support to the flexible
blower
motor cover.
10. Install the front passenger interior floor courtesy light. 11. Install the front passenger side
interior kick panel molding. 12. Install the front passenger door sill molding.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Blower Motor: > 06-01-38-001C > Jul > 10 > A/C - Blower Motor
Clicking/Chirping/Whirring Noises > Page 8481
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations >
Instrument Panel/Center Console Component Views
Blower Motor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Behind the I/P Components
1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation
Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 8484
Blower Motor: Locations Harness Routing Views
Harness Routing Views
HVAC Harness Routing
1 - Evaporator Temperature Sensor (C60) 2 - X203 (I/P Harness to the HVAC Harness) 3 Recirculation Actuator (C60) 4 - Blower Motor 5 - J202 6 - Blower Motor Resistor Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions
Blower Motor: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8487
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8488
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Blower Motor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8596
5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8597
3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8598
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8599
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8600
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8601
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8602
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8603
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8604
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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Diagram Information and Instructions > Page 8605
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8606
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8607
6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8608
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8609
2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8610
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8611
6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8612
2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8613
4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8614
6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8615
8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8616
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8617
2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8618
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8619
4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8620
6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8621
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8622
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Diagram Information and Instructions > Page 8623
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8624
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8625
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8626
1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8627
3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8628
5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8629
7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8630
9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8631
11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8632
13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8633
15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8634
17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8635
19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8636
21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8637
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8638
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8639
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8640
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Diagram Information and Instructions > Page 8641
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
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Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8655
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8656
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8657
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 8658
Blower Motor: Connector Views
Component Connector End Views
Blower Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page
8659
Blower Motor: Service and Repair
Blower Motor Replacement
Removal Procedure
1. Remove the right hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement Right Side (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
2. Remove the blower motor mounting screws. 3. Remove the blower motor cooling tube (2). 4.
Disconnect the blower motor electrical connector (4). 5. Remove the blower motor (3).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page
8660
1. Install the blower motor (3). 2. Connect the blower motor electrical connector (4). 3. Install the
blower motor cooling tube (2).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the blower motor mounting screws. Tighten the screws to 2 Nm (18 lb in). 5. Install the
right hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See:
Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information >
Locations > Instrument Panel/Center Console Component Views
Blower Motor Resistor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Behind the I/P Components
1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation
Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information >
Locations > Instrument Panel/Center Console Component Views > Page 8665
Blower Motor Resistor: Locations Harness Routing Views
Harness Routing Views
HVAC Harness Routing
1 - Evaporator Temperature Sensor (C60) 2 - X203 (I/P Harness to the HVAC Harness) 3 Recirculation Actuator (C60) 4 - Blower Motor 5 - J202 6 - Blower Motor Resistor Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information >
Locations > Page 8666
Blower Motor Resistor: Diagrams
Component Connector End Views
Blower Motor Resistor Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information >
Locations > Page 8667
Blower Motor Resistor: Service and Repair
Blower Motor Resistor Assembly Replacement
Removal Procedure
1. Disconnect the blower motor resistor electrical connector (1). 2. Remove the blower motor
resistor mounting screws. 3. Remove the blower motor resistor (2).
Installation Procedure
1. Install the blower motor resistor (2).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information >
Locations > Page 8668
2. Install the blower motor resistor mounting screws. Tighten the screws to 1.9 Nm (17 lb in). 3.
Connect the blower motor resistor electrical connector (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service
and Repair
Cabin Ventilation Grille: Service and Repair
Pressure Relief Valve Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams
Compressor Clutch: Diagrams
Component Connector End Views
A/C Compressor Clutch (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component
Information > Service and Repair
Compressor Clutch Hub: Service and Repair
Compressor Clutch Plate/Hub Assembly Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations
Compressor Clutch Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations > Page 8682
Compressor Clutch Relay: Service and Repair
Compressor Relay Replacement
Removal Procedure
1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay
(2).
Installation Procedure
1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and
Repair
Condenser HVAC: Service and Repair
Air Conditioning Condenser Replacement
Tools Required
J 39400-A Halogen Leak Detector
Removal Procedure
1. Remove the radiator. Refer to Radiator Replacement (See: Engine, Cooling and
Exhaust/Cooling System/Radiator/Service and Repair). 2. Recover the refrigerant. Refer to
Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and
Recharging).
3. Remove the receiver dryer. 4. Remove the condenser inlet hose bolt. 5. Remove the condenser
inlet hose. 6. Remove the condenser outlet hose bolt. 7. Remove the condenser outlet hose. 8.
Remove the condenser from mounts on the radiator (1). 9. Remove the condenser.
Installation Procedure
Note: If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant
System Capacities (See: Specifications/Capacity Specifications) for the capacity information.
1. Install the condenser to the radiator. 2. If replacing the condenser, transfer the components from
the old condenser as necessary.
3. Install the condenser to the mounts on the radiator (1).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the condenser retaining bolts to the radiator. Tighten the bolts to 28 Nm (21 lb ft). 5. Install
the receiver dyer. 6. Install the condenser inlet hose. 7. Install the condenser inlet hose bolt.
Tighten the bolts to 20 Nm (15 lb ft). 8. Install the condenser outlet hose. 9. Install the condenser
outlet hose bolt. Tighten the bolts to 20 Nm (15 lb ft).
10. Install the radiator. Refer to Radiator Replacement (See: Engine, Cooling and Exhaust/Cooling
System/Radiator/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and
Repair > Page 8686
11. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (See:
Service and Repair/Refrigerant Recovery and
Recharging).
12. Leak test the fittings of the components using the J 39400-A .
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Locations > Harness Routing Views
Control Assembly: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Locations > Harness Routing Views > Page 8691
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Locations > Harness Routing Views > Page 8692
Control Assembly: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Locations > Page 8693
Control Assembly: Diagrams
Component Connector End Views
HVAC Control Module X1
HVAC Control Module X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Locations > Page 8694
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Locations > Page 8695
Control Assembly: Service and Repair
Heater and Air Conditioning Control Replacement
Removal Procedure
1. Remove the accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement
(See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
2. Remove the screws (7,2) from the HVAC control assembly. 3. Remove the HVAC control
assembly from the instrument panel.
4. Disconnect the mode cable from the HVAC control assembly. Refer to Mode Control Cable
Replacement (See: Air Door/Air Door Cable/Service
and Repair/Mode Control Cable Replacement).
5. Disconnect the temperature cable from the HVAC control assembly. Refer to Temperature
Control Cable Replacement (See: Air Door/Air Door
Cable/Service and Repair/Temperature Control Cable Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Locations > Page 8696
6. Disconnect the HVAC control assembly electrical connectors. 7. Remove the HVAC control
assembly.
Installation Procedure
1. Install the HVAC control assembly. 2. Connect the HVAC control assembly electrical connectors.
Note: Do not bend the mode and temperature cables.
3. Connect the mode cable to the HVAC control assembly. Refer to Mode Control Cable
Replacement (See: Air Door/Air Door Cable/Service and
Repair/Mode Control Cable Replacement).
4. Connect the temperature cable to the HVAC control assembly. Refer to Temperature Control
Cable Replacement (See: Air Door/Air Door
Cable/Service and Repair/Temperature Control Cable Replacement).
5. Install the HVAC control assembly to the instrument panel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Locations > Page 8697
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the HVAC control assembly screws. Tighten the screws to 1.9 Nm (18 lb in). 7. Install the
accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component
Information > Service and Repair > Sealing Washer Replacement
A/C Coupler O-ring: Service and Repair Sealing Washer Replacement
Sealing Washer Replacement
Removal Procedure
1. Remove the seal washer from the A/C refrigerant component.
Important: Cap or tape the open A/C refrigerant components immediately to prevent system
contamination.
2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3.
Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
Important: DO NOT reuse sealing washer.
4. Discard the sealing washer.
Installation Procedure
Important: Flat washer type seals do not require lubrication.
1. Inspect the new seal washer for any signs of cracks, cuts, or damage.
Do not use a damaged seal washer.
2. Remove the cap or tape from the A/C refrigerant components.
3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4.
Carefully install the new seal washer onto the A/C refrigerant component.
The washer must completely bottom against the surface of the fitting.
Important: After tightening the A/C components, there should be a slight sealing washer gap of
approximately 1.2 mm (3/64 in) between the A/C line and the A/C component.
5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component
Information > Service and Repair > Sealing Washer Replacement > Page 8703
A/C Coupler O-ring: Service and Repair O-Ring Replacement
O-Ring Replacement
Removal Procedure
1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure
* For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1).
* For banjo style fittings remove the bolt retaining the banjo type fitting.
2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs
of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant
components for damage or burrs. Repair if necessary.
Important: Cap or tape the open A/C refrigerant components immediately to prevent system
contamination.
5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal.
Installation Procedure
1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2.
Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth,
carefully clean the sealing surfaces of the A/C refrigerant components.
Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring
seal to enter the refrigerant system.
4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.
Important: DO NOT reuse O-ring seals.
5. Carefully slide the new O-ring seal onto the A/C refrigerant component.
6. The O-ring seal must be fully seated.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component
Information > Service and Repair > Sealing Washer Replacement > Page 8704
7. Assemble the A/C components.
Refer to the appropriate repair procedure.
* For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1)
to specification.
* For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations
Evaporator Case: Locations
Instrument Panel/Center Console Component Views
Behind the I/P Components
1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation
Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From
(HVAC) System
Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System
TECHNICAL
Bulletin No.: 99-01-39-004C
Date: June 12, 2009
Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating)
Models:
1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All
Equipped with Air Conditioning
Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard
Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC).
Condition
Some customers may comment about musty odors emitted from the Heating, Ventilation and Air
Conditioning (HVAC) system at vehicle start-up in hot, humid conditions.
Cause
This condition may be caused by condensate build-up on the evaporator core, which does not
evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on
the evaporator core. When the blower motor fan is turned on, the microbial growth may release an
unpleasant musty odor into the passenger compartment.
There are several other possible sources of a musty odor in a vehicle. A common source is a water
leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow
the procedures in SI for identifying and correcting water leaks and air inlet inspection.
The procedure contained in this bulletin is only applicable if the odor source has been determined
to be microbial growth on the evaporator core inside the HVAC module.
Correction
Many vehicles currently incorporate an afterblow function within the HVAC control module
software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the
evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to
confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded
afterblow feature, as defined in the SI document for that specific vehicle model, model year and
specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in
areas prone to high humidity conditions may benefit from having the afterblow enabled calibration
installed prior to any customer comment.
Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may
be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876).
Important When installing the Electronic Evaporator Dryer Module, you MUST use the included
electrical splice connectors to ensure a proper splice. Complete detailed installation instructions
and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer
Module may be installed underhood if it is protected from extreme heat and water splash areas.
To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to
eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the
following procedure:
Vehicle and Applicator Tool Preparation
1. The evaporator core must be dry. This may be accomplished by disabling the compressor and
running the blower fan on the recirc heat setting for
an extended period of time.
Note Compressor engagement will cause the evaporator core to remain wet and will prevent full
adherence of the Coiling Coil Coating to the evaporator core surfaces.
2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From
(HVAC) System > Page 8716
3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air
filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product
may clog the filter. If the
cabin air filter appears to have little or no remaining life, suggest a replacement to your customer.
5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE
COOLING COIL COATING INTO THE
BLOWER MOTOR COOLING TUBE.
6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line
operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well.
Screw the bottle onto the cap on the applicator tool's pick-up tube.
Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil
slightly in the bottom of a 120 ml (4 oz) bottle.
8. Use one of the following three methods to apply the Cooling Coil Coating.
Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil
Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)).
Application Through Blower Motor Control Module Opening
- Remove the blower motor control module (blower motor resistor). Refer to the applicable
procedure in SI.
- Clean any debris or foreign material from inside the HVAC module and on the evaporator core
surface.
- Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower
motor control module (blower motor resistor) opening.
- Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and
surrounding gasket surfaces.
- When the application is complete, install the blower motor blower motor control module (blower
motor control module).
Application Through Blower Motor Opening
- Remove the blower motor. Refer to the applicable blower motor removal procedure in SI.
- Clean any debris or foreign material from inside the HVAC module and on the evaporator core
surface.
- Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening.
- Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and
surrounding gasket surfaces.
- When the application is complete, install the blower motor.
Application Through a Hole in the HVAC Module
- If neither of the two previous application methods are available, it may be necessary to drill a hole
in the HVAC module.
- Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10
mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and
the blower motor fan.
- With the air distribution vents closed and the blower motor fan speed on HIGH, insert the
applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the
evaporator core.
- Use a GM approved RTV sealant to plug the hole in the HVAC module.
9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately
10 minutes, with the compressor disabled,
HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and
one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the
evaporator core surface.
10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the
tool. Be sure to spray warm water through the
nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it
will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and
rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged ,
the Cooling Coil Coating will not flow through the applicator tool.
11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system
operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from
underneath the vehicle. 15. Reinstall the cabin air filter if necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From
(HVAC) System > Page 8717
Parts Information
Important The Cooling Coil Coating listed below is the only GM approved product for use under
warranty as an evaporator core disinfectant and for the long term control of evaporator core
microbial growth.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors
Emitted From (HVAC) System
Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System
TECHNICAL
Bulletin No.: 99-01-39-004C
Date: June 12, 2009
Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating)
Models:
1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All
Equipped with Air Conditioning
Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard
Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC).
Condition
Some customers may comment about musty odors emitted from the Heating, Ventilation and Air
Conditioning (HVAC) system at vehicle start-up in hot, humid conditions.
Cause
This condition may be caused by condensate build-up on the evaporator core, which does not
evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on
the evaporator core. When the blower motor fan is turned on, the microbial growth may release an
unpleasant musty odor into the passenger compartment.
There are several other possible sources of a musty odor in a vehicle. A common source is a water
leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow
the procedures in SI for identifying and correcting water leaks and air inlet inspection.
The procedure contained in this bulletin is only applicable if the odor source has been determined
to be microbial growth on the evaporator core inside the HVAC module.
Correction
Many vehicles currently incorporate an afterblow function within the HVAC control module
software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the
evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to
confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded
afterblow feature, as defined in the SI document for that specific vehicle model, model year and
specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in
areas prone to high humidity conditions may benefit from having the afterblow enabled calibration
installed prior to any customer comment.
Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may
be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876).
Important When installing the Electronic Evaporator Dryer Module, you MUST use the included
electrical splice connectors to ensure a proper splice. Complete detailed installation instructions
and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer
Module may be installed underhood if it is protected from extreme heat and water splash areas.
To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to
eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the
following procedure:
Vehicle and Applicator Tool Preparation
1. The evaporator core must be dry. This may be accomplished by disabling the compressor and
running the blower fan on the recirc heat setting for
an extended period of time.
Note Compressor engagement will cause the evaporator core to remain wet and will prevent full
adherence of the Coiling Coil Coating to the evaporator core surfaces.
2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the
vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors
Emitted From (HVAC) System > Page 8723
3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air
filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product
may clog the filter. If the
cabin air filter appears to have little or no remaining life, suggest a replacement to your customer.
5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE
COOLING COIL COATING INTO THE
BLOWER MOTOR COOLING TUBE.
6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line
operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well.
Screw the bottle onto the cap on the applicator tool's pick-up tube.
Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil
slightly in the bottom of a 120 ml (4 oz) bottle.
8. Use one of the following three methods to apply the Cooling Coil Coating.
Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil
Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)).
Application Through Blower Motor Control Module Opening
- Remove the blower motor control module (blower motor resistor). Refer to the applicable
procedure in SI.
- Clean any debris or foreign material from inside the HVAC module and on the evaporator core
surface.
- Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower
motor control module (blower motor resistor) opening.
- Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and
surrounding gasket surfaces.
- When the application is complete, install the blower motor blower motor control module (blower
motor control module).
Application Through Blower Motor Opening
- Remove the blower motor. Refer to the applicable blower motor removal procedure in SI.
- Clean any debris or foreign material from inside the HVAC module and on the evaporator core
surface.
- Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening.
- Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and
surrounding gasket surfaces.
- When the application is complete, install the blower motor.
Application Through a Hole in the HVAC Module
- If neither of the two previous application methods are available, it may be necessary to drill a hole
in the HVAC module.
- Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10
mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and
the blower motor fan.
- With the air distribution vents closed and the blower motor fan speed on HIGH, insert the
applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the
evaporator core.
- Use a GM approved RTV sealant to plug the hole in the HVAC module.
9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately
10 minutes, with the compressor disabled,
HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and
one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the
evaporator core surface.
10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the
tool. Be sure to spray warm water through the
nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it
will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and
rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged ,
the Cooling Coil Coating will not flow through the applicator tool.
11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system
operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from
underneath the vehicle. 15. Reinstall the cabin air filter if necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors
Emitted From (HVAC) System > Page 8724
Parts Information
Important The Cooling Coil Coating listed below is the only GM approved product for use under
warranty as an evaporator core disinfectant and for the long term control of evaporator core
microbial growth.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > Page 8725
Evaporator Core: Service and Repair
Air Conditioning Evaporator Core Replacement
Removal Procedure
1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See:
Housing Assembly HVAC/Service and Repair). 2. Remove the screws to separate the HVAC
module assembly halves. 3. Remove the evaporator temperature sensor control module screw. 4.
Reposition the evaporator temperature sensor control module.
5. Separate the HVAC module assembly (1, 4). 6. Remove the evaporator temperature sensor from
the evaporator.
7. Remove the evaporator core (1) from the HVAC module assembly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > Page 8726
Installation Procedure
Note: If replacing the evaporator core, add the refrigerant oil to the evaporator core. Refer to
Refrigerant System Capacities (See: Specifications/Capacity Specifications) for system capacity
information.
1. Install the seal between the HVAC module assembly halves.
2. Install the evaporator core (1) to the HVAC module assembly. 3. Install the evaporator
temperature sensor to the evaporator core.
4. Assemble the HVAC module assembly.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Install the screws to join the HVAC module assembly halves. Tighten the screws to 1.9 Nm (17
lb in). 6. Install the evaporator temperature sensor control module screw. Tighten the to 1.9 Nm (17
lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > Page 8727
7. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See:
Housing Assembly HVAC/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Service
and Repair
Evaporator Drain Tube: Service and Repair
Evaporator Tube Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Locations > Harness Routing Views
Evaporator Temperature Sensor / Switch: Locations Harness Routing Views
Harness Routing Views
HVAC Harness Routing
1 - Evaporator Temperature Sensor (C60) 2 - X203 (I/P Harness to the HVAC Harness) 3 Recirculation Actuator (C60) 4 - Blower Motor 5 - J202 6 - Blower Motor Resistor Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Locations > Harness Routing Views > Page 8735
Evaporator Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component
Views
Instrument Panel/Center Console Component Views
Behind the I/P Components
1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation
Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Locations > Page 8736
Evaporator Temperature Sensor / Switch: Diagrams
Component Connector End Views
Evaporator Temperature Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Locations > Page 8737
Evaporator Temperature Sensor / Switch: Service and Repair
Evaporator Temperature Sensor Replacement
Removal Procedure
1. Remove the radio. Refer to Radio Replacement (See: Accessories and Optional
Equipment/Radio, Stereo, and Compact
Disc/Radio/Stereo/Service and Repair/Radio Replacement).
2. Remove the mounting screw from the evaporator temperature control module. 3. Disconnect the
electrical connector from the control module. 4. Cut the evaporator temperature sensor wire near
the control module.
Note: *
Note the mounting position of the evaporative temperature sensor (a, b) and use these
measurements upon installation.
* If you are replacing only the control module, proceed to Step 4 of the Installation Procedure.
5. Remove the evaporator core. Refer to Air Conditioning Evaporator Core Replacement (See:
Evaporator Core/Service and Repair). 6. Using needle nose pliers, carefully remove the evaporator
temperature sensor from the evaporator core.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Locations > Page 8738
1. Install the evaporator temperature sensor to the evaporator core. Place the sensor
approximately 3.5 cm (1.4 in) from the side (a) and 5 cm (2 in)
from the bottom (b) corner of the evaporator core.
Note: Improper wire alignment will pinch and may cut the sensor wires.
2. Align the evaporator temperature sensor wires with the opening in the upper HVAC module
case. 3. Install the evaporator core. Refer to Air Conditioning Evaporator Core Replacement (See:
Evaporator Core/Service and Repair). 4. Cut the evaporator temperature sensor from the
replacement assembly. 5. Connect the original sensor wire to the replacement assembly. Refer to
Splicing Copper Wire Using Splice Sleeves (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Connect the electrical connector to the evaporator temperature control module.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. Install the mounting screw to the control module. Tighten the screw to 1.9 Nm (17 lb in). 8. Install
the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo,
and Compact Disc/Radio/Stereo/Service
and Repair/Radio Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair
Expansion Block/Orifice Tube: Service and Repair
Air Conditioning Evaporator Thermal Expansion Valve Replacement
Special Tools
J 39400-A Halogen Leak Detector
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and
Repair/Refrigerant Recovery and Recharging). 2. Remove the nut from the TXV mounting stud.
3. Remove the evaporator tube and the compressor suction hose from the TXV. 4. Remove and
discard the seal washers.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > Page 8742
5. Remove the TXV bolts. 6. Remove the TXV. 7. Remove and discard the seal washers.
Installation Procedure
1. Install new seal washers to the evaporator core fittings. Refer to Sealing Washer Replacement
(See: Coupler HVAC/A/C Coupler O-ring/Service
and Repair/Sealing Washer Replacement).
2. Install the TXV.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the TXV bolts. Tighten the bolts to 7 Nm (62 lb in).
4. Install new sealing washers on the evaporator tube and the compressor suction hose fittings.
Refer to Sealing Washer Replacement (See: Coupler
HVAC/A/C Coupler O-ring/Service and Repair/Sealing Washer Replacement).
5. Install the evaporator tube and the compressor suction hose to the TXV.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > Page 8743
6. Install the TXV nut. Tighten the nut to 20 Nm (15 lb ft). 7. Evacuate and charge the refrigerant
system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant
Recovery and
Recharging).
8. Leak test the fittings using the J 39400-A .
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair
Heater Core: Service and Repair
Heater Core Replacement
Removal Procedure
1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See:
Housing Assembly HVAC/Service and Repair).
2. Remove the heater core pipes clamp screw (3). 3. Remove the heater core pipes clamp (2). 4.
Remove the heater core clamp screws. 5. Remove the heater core clamp (2). 6. Remove the
heater core from the HVAC module.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair
> Page 8747
1. Install the heater core to the HVAC module. 2. Install the heater core clamp (2).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the heater core clamp screws. Tighten the screws to 1.9 Nm (17 lb in). 4. Install the heater
core pipes clamp (2). 5. Install the heater core pipes clamp screw (3). Tighten the screw to 20 Nm
(15 lb ft). 6. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement
(See: Housing Assembly HVAC/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement
Heater Hose: Service and Repair Heater Inlet Hose Replacement
Heater Inlet Hose Replacement
Tools Required
* J 38185 Hose Clamp Pliers
* J 43181 Heater Line Quick Connect Release Tool
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service
and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair).
2. Using the J 43181 , release the inlet heater hose quick connect (1) from the heater core inlet. 3.
Position the inlet heater hose clamp (4) at the engine block using J 38185 . 4. Remove the heater
inlet hose (3) from the inlet hose fitting (6) at the engine block. 5. Remove the heater inlet hose (3).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement > Page 8752
1. Apply coolant to the end of the heater inlet hose (5).
Important: When installing a new heater inlet hose, place the clamps on the hose before installing
the hose to the inlet hose fitting at the engine block.
2. Install the heater inlet hose (3) to the inlet hose fitting (6) at the engine block. 3. Position the inlet
heater hose clamp (4) at the engine block using J 38185 . 4. Install the heater inlet hose (3) to the
heater core inlet. 5. Press the quick connect (1) onto the heater core inlet until fully seated. 6. Fill
the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement > Page 8753
Heater Hose: Service and Repair Heater Outlet Hose Replacement
Heater Outlet Hose Replacement
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service
and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair).
2. Remove the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (4WD 5.3L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 5.3L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement).
3. Remove the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and
Charging/Charging System/Alternator/Service and
Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and
Charging/Charging System/Alternator/Service and Repair/Generator Replacement).
4. Using the J 38185 disconnect the outlet hose from the heater core outlet tube. 5. Remove the
heater outlet hose from the heater core.
6. Position the outlet heater hose clamp (6) at the water pump using J 38185 . 7. Remove the
heater outlet hose (7) from the outlet hose fitting. 8. Remove the heater outlet hose.
Installation Procedure
1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3.
Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185 . 4. Install the
heater outlet hose to the heater core. 5. Position the outlet heater hose clamp at the heater core
using J 38185 . 6. Install the transmission. Refer to Transmission Replacement (4WD 2.9L and
3.7L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (4WD 5.3L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD 5.3L) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission
Replacement (2WD
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement > Page 8754
2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and
Repair/Removal and Replacement).
7. Install the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and
Charging/Charging System/Alternator/Service and
Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and
Charging/Charging System/Alternator/Service and Repair/Generator Replacement).
8. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service
and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement > Page 8755
Heater Hose: Service and Repair Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe
Replacement
Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement > Page 8756
Heater Hose: Service and Repair Heater Inlet Pipe Replacement
Heater Inlet Pipe Replacement
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
2. Using the J 38185 , reposition the heater hose outlet clamp from the heater pipe inlet. 3.
Remove the heater hose outlet from the heater pipe inlet. 4. Remove the exhaust heat shield.
Refer to Exhaust Manifold Heat Shield Replacement (LLV) ()Exhaust Manifold Heat Shield
Replacement (LLR)
().
5. Remove the heater inlet pipe bolt. 6. Remove the heater inlet pipe.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement > Page 8757
1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet
hose fitting threads.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the heater outlet hose fitting. Tighten the heater outlet hose fitting to 45 Nm (33 lb ft). 3.
Install the heater hose outlet to the heater pipe inlet. 4. Using the J 38185 , reposition the heater
hose outlet clamp to the heater pipe inlet. 5. Install the exhaust heat shield. Refer to Exhaust
Manifold Heat Shield Replacement (LLV) ()Exhaust Manifold Heat Shield Replacement (LLR)
().
6. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement > Page 8758
Heater Hose: Service and Repair Heater Outlet Pipe Replacement
Heater Outlet Pipe Replacement
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
2. Using the J 38185 , reposition the heater hose inlet clamp from the heater pipe outlet. 3.
Remove the heater hose inlet from the heater pipe outlet.
4. Loosen the heater pipe outlet. 5. Remove the heater pipe outlet.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement > Page 8759
1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet
hose fitting threads.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the heater outlet hose fitting. Tighten the heater outlet hose fitting to 45 Nm (33 lb ft). 3.
Install the heater hose inlet to the heater pipe outlet. 4. Using the J 38185 , reposition the heater
hose inlet clamp to the heater pipe outlet. 5. Fill the engine cooling system. Refer to Cooling
System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling
and Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-01-38-002 > May > 09 > A/C - Moan/Whine Noise Under
Heavy Load
Hose/Line HVAC: Customer Interest A/C - Moan/Whine Noise Under Heavy Load
TECHNICAL
Bulletin No.: 09-01-38-002
Date: May 14, 2009
Subject: A/C Moan and/or Whine Noise Under Heavy Load Condition (Replace A/C Suction Hose
With Updated Design)
Models:
2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3 , H3T, H3G Export All Equipped
with Engine RPO LH8
Condition
Some customers may comment on a moan and/or a whine type noise when the A/C compressor is
engaged during high system loads. These high load operating conditions include high ambient
temperatures, extended periods of idle operation and towing applications. The noise will stop
immediately when the compressor is disengaged.
Cause
This condition may be caused by the factory installed A/C suction hose lacking sufficient noise
dampening.
Correction
Install a new A/C suction hose assembly. This new hose assembly has an improved noise
dampening design. Refer to Suction Hose Replacement (LH8) in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-01-38-002 > May > 09 > A/C - Moan/Whine
Noise Under Heavy Load
Hose/Line HVAC: All Technical Service Bulletins A/C - Moan/Whine Noise Under Heavy Load
TECHNICAL
Bulletin No.: 09-01-38-002
Date: May 14, 2009
Subject: A/C Moan and/or Whine Noise Under Heavy Load Condition (Replace A/C Suction Hose
With Updated Design)
Models:
2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3 , H3T, H3G Export All Equipped
with Engine RPO LH8
Condition
Some customers may comment on a moan and/or a whine type noise when the A/C compressor is
engaged during high system loads. These high load operating conditions include high ambient
temperatures, extended periods of idle operation and towing applications. The noise will stop
immediately when the compressor is disengaged.
Cause
This condition may be caused by the factory installed A/C suction hose lacking sufficient noise
dampening.
Correction
Install a new A/C suction hose assembly. This new hose assembly has an improved noise
dampening design. Refer to Suction Hose Replacement (LH8) in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Discharge Hose Replacement
Hose/Line HVAC: Service and Repair Discharge Hose Replacement
Discharge Hose Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Discharge Hose Replacement > Page 8775
Hose/Line HVAC: Service and Repair Suction Hose Replacement
Suction Hose Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Discharge Hose Replacement > Page 8776
Hose/Line HVAC: Service and Repair Suction Screen Replacement
Suction Screen Replacement
Tools Required
J 44551 Suction Screen Kit
Removal Procedure
Important: Suction screens are intended to be installed in the suction hose after a major
compressor failure.
1. Remove the A/C suction hose from the A/C compressor. Refer to Suction Hose Replacement
(LH8) (See: Suction Hose Replacement)Suction
Hose Replacement (LLV, LLR) (See: Suction Hose Replacement).
2. Using the J-44551-9 Universal Removal Tool, place the tip of the tool under the inside edge of
the compression band of the suction screen and the
cushioning fulcrum pad against the open end of the hose or manifold fitting.
Important: Do not damage the end of the hose or manifold.
3. Pry upward on the band and move the tool around the diameter of the screen as necessary to
remove the screen.
Installation Procedure
1. Using a caliper that reads to 3 decimal places, measure the ID of the suction hose or manifold
suction fitting. To determine the correct size screen
for the application, refer to Compressor Suction Screen and Tool Selection Specifications (See:
Specifications/Mechanical Specifications/Heating, Ventilation, and Air Conditioning/Compressor
Suction Screen and Tool Selection Specifications).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Discharge Hose Replacement > Page 8777
2. Select and install the correct mandrel (1) on the threaded portion of the installation tool bolt:
* The brass Universal Mandrel is for use on hose fittings with a smooth bore where the screen
installs flush with the end of the fitting.
* The 11.96 mm (0.471 in) Mandrel is only for the 11.96 mm (0.471 in) screen in hose fittings with
an internal hourglass shape where the screen installs at the recessed, reduced diameter point.
3. Install the 11.96 mm (0.471 in) screen in the middle of the reduced diameter point of the fitting.
4. Place the suction hose fitting or suction hose side of the manifold into the installation tool fixture
J-44551-5 (3) so it is supported by the tools legs.
Important: Correct placement of the J-44551-5 is critical.
5. Lubricate the A/C suction screen with the applicable refrigerant oil. 6. Align the screen (2),
basket first; into the suction hose bore then hand tighten the bolt until contact is made between the
hose, screen and tool. 7. Turn the bolt of the installation tool clockwise pressing the screen into the
bore until the mandrel shoulder contacts the end of the hose fitting. 8. Unscrew the bolt and
remove the installation tool from the hose or manifold.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Discharge Hose Replacement > Page 8778
Important: Clean the surface to be used for attaching the label.
9. Install the J-44551-1 Suction Screen Notification Label.
10. Install the A/C hose to the A/C compressor. Refer to Suction Hose Replacement (LH8) (See:
Suction Hose Replacement)Suction Hose
Replacement (LLV, LLR) (See: Suction Hose Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair
Housing Assembly HVAC: Service and Repair
HVAC Module Assembly Replacement
Tools Required
* J 43181 Heater Line Quick Connect Release Tool
* J 39400-A Halogen Leak Detector
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service
and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair).
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and
Repair/Refrigerant Recovery and Recharging). 3. Remove the instrument panel (I/P) carrier. Refer
to Instrument Panel Carrier Replacement (See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
4. Release the heater hose clamps using J 43181 . 5. Disconnect the heater hose quick connects
(2) and (3) from the heater core.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair > Page 8782
6. Remove the retaining nut from the TXV stud. 7. Remove the evaporator tube and suction hose
from the TXV. 8. Remove the radio antenna from the HVAC module. 9. Reposition the carpet.
10. Remove rear floor duct. Refer to Rear Floor Air Outlet Replacement (See: Air Register/Service
and Repair/Rear Floor Air Outlet Replacement). 11. Remove the HVAC module retaining nuts from
the cowl. 12. Remove the HVAC module assembly.
Installation Procedure
1. Install the HVAC module assembly. 2. Install the HVAC module retaining nuts from the cowl.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the HVAC module retaining nuts. Tighten the nut to 4.5 Nm (40 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair > Page 8783
4. If replacing the HVAC module assembly (8), transfer the components from the old HVAC module
assembly as necessary. 5. Install the HVAC module assembly (8). 6. Install rear floor duct. Refer to
Rear Floor Air Outlet Replacement (See: Air Register/Service and Repair/Rear Floor Air Outlet
Replacement). 7. Reposition the carpet. 8. Install the radio antenna to the HVAC module.
9. Connect the heater hose quick connects (2) and (3) to the heater core.
10. Install the evaporator tube and suction hose to the TXV. 11. Install the retaining nut to the TXV
stud. 12. Tighten the retaining nut. Tighten the nut to 4.5 Nm (40 lb in). 13. Install the I/P carrier.
Refer to Instrument Panel Carrier Replacement (See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument
Panel/Service and Repair).
14. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (See:
Service and Repair/Refrigerant Recovery and
Recharging).
15. Leak test the fittings of the components using the J 39400-A . 16. Refill the engine coolant.
Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service
and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and
Repair
Receiver Dryer: Service and Repair
Receiver and Dehydrator Replacement
Special Tools
J 39400-A Halogen Leak Detector
Removal Procedure
1. Recover refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and
Repair/Refrigerant Recovery and Recharging). 2. Remove the grille. Refer to Grille Replacement
(See: Body and Frame/Grille/Service and Repair).
Warning
Do not remove hoses or lines before system is fully discharged. System may be under pressure
and contact with R134a may cause personal injury.
3. Remove the condenser hose bolt from the receiver dehydrator. 4. Remove the condenser hose
from the receiver dehydrator. 5. Remove the evaporator tube bolt from the receiver dehydrator. 6.
Remove the evaporator tube from the receiver dehydrator. 7. Install caps on the condenser hose
and the evaporator tube assembly to prevent moisture entry and oil spillage. 8. Remove the
receiver dehydrator bracket bolts and the receiver dehydrator assembly. 9. Loosen the receiver
dehydrator clamp bolt and remove receiver dehydrator.
Installation Procedure
1. If replacing the receiver dehydrator add the appropriate amount of PAG oil to the system. Refer
to Refrigerant System Capacities (See:
Specifications/Capacity Specifications) for capacity information.
2. Install the receiver dehydrator bottle into the clamp but do not tighten. 3. Install new O-rings.
Refer to O-Ring Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/O-Ring
Replacement).
Caution: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation
through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If
lubricants other than those specified are used, compressor failure and/or fitting seizure may result.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the receiver dehydrator bracket bolts. 5. Tighten the receiver/dehydrator clamp bolt.
Tighten the bolt to 5 Nm (44 lb in). 6. Remove the condenser hose to condenser cap and plug and
install a new seal washer. Refer to Sealing Washer Replacement (See: Coupler
HVAC/A/C Coupler O-ring/Service and Repair/Sealing Washer Replacement).
7. Install the evaporator tube to the receiver dehydrator. 8. Install the evaporator tube bolt to the
receiver dehydrator. Tighten the bolt to 20 Nm (15 lb ft). 9. Install the condenser hose to the
receiver dehydrator.
10. Hand start the condenser hose bolt to the receiver dehydrator. Tighten the bolt to 20 Nm (15 lb
ft). 11. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging
(See: Service and Repair/Refrigerant Recovery and
Recharging).
12. Using the J 39400-A leak test the fittings of the component. 13. Install the grille. Refer to Grille
Replacement (See: Body and Frame/Grille/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Capacity Specifications
Refrigerant: Capacity Specifications
Refrigerant System Capacities
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Capacity Specifications > Page 8791
Refrigerant: Fluid Type Specifications
Refrigerant System Capacities
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
Refrigerant System Capacities
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 8796
Refrigerant Oil: Fluid Type Specifications
Refrigerant System Capacities
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Locations > Front of Vehicle/Engine Compartment Component Views
Refrigerant Pressure Sensor / Switch: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 8801
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 8802
Refrigerant Pressure Sensor / Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 8803
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 8804
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Locations > Page 8805
Refrigerant Pressure Sensor / Switch: Diagrams
Component Connector End Views
A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Locations > Page 8806
Refrigerant Pressure Sensor / Switch: Service and Repair
Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations
Compressor Clutch Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 8811
Compressor Clutch Relay: Service and Repair
Compressor Relay Replacement
Removal Procedure
1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay
(2).
Installation Procedure
1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC >
Component Information > Locations
System Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Locations > Harness Routing Views
Evaporator Temperature Sensor / Switch: Locations Harness Routing Views
Harness Routing Views
HVAC Harness Routing
1 - Evaporator Temperature Sensor (C60) 2 - X203 (I/P Harness to the HVAC Harness) 3 Recirculation Actuator (C60) 4 - Blower Motor 5 - J202 6 - Blower Motor Resistor Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Locations > Harness Routing Views > Page 8820
Evaporator Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component
Views
Instrument Panel/Center Console Component Views
Behind the I/P Components
1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation
Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Locations > Page 8821
Evaporator Temperature Sensor / Switch: Diagrams
Component Connector End Views
Evaporator Temperature Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Locations > Page 8822
Evaporator Temperature Sensor / Switch: Service and Repair
Evaporator Temperature Sensor Replacement
Removal Procedure
1. Remove the radio. Refer to Radio Replacement (See: Accessories and Optional
Equipment/Radio, Stereo, and Compact
Disc/Radio/Stereo/Service and Repair/Radio Replacement).
2. Remove the mounting screw from the evaporator temperature control module. 3. Disconnect the
electrical connector from the control module. 4. Cut the evaporator temperature sensor wire near
the control module.
Note: *
Note the mounting position of the evaporative temperature sensor (a, b) and use these
measurements upon installation.
* If you are replacing only the control module, proceed to Step 4 of the Installation Procedure.
5. Remove the evaporator core. Refer to Air Conditioning Evaporator Core Replacement (See:
Evaporator Core/Service and Repair). 6. Using needle nose pliers, carefully remove the evaporator
temperature sensor from the evaporator core.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Locations > Page 8823
1. Install the evaporator temperature sensor to the evaporator core. Place the sensor
approximately 3.5 cm (1.4 in) from the side (a) and 5 cm (2 in)
from the bottom (b) corner of the evaporator core.
Note: Improper wire alignment will pinch and may cut the sensor wires.
2. Align the evaporator temperature sensor wires with the opening in the upper HVAC module
case. 3. Install the evaporator core. Refer to Air Conditioning Evaporator Core Replacement (See:
Evaporator Core/Service and Repair). 4. Cut the evaporator temperature sensor from the
replacement assembly. 5. Connect the original sensor wire to the replacement assembly. Refer to
Splicing Copper Wire Using Splice Sleeves (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Connect the electrical connector to the evaporator temperature control module.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. Install the mounting screw to the control module. Tighten the screw to 1.9 Nm (17 lb in). 8. Install
the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo,
and Compact Disc/Radio/Stereo/Service
and Repair/Radio Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure
Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
Refrigerant Pressure Sensor / Switch: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure
Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 8828
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure
Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 8829
Refrigerant Pressure Sensor / Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure
Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 8830
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure
Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views >
Page 8831
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure
Sensor / Switch, HVAC > Component Information > Locations > Page 8832
Refrigerant Pressure Sensor / Switch: Diagrams
Component Connector End Views
A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure
Sensor / Switch, HVAC > Component Information > Locations > Page 8833
Refrigerant Pressure Sensor / Switch: Service and Repair
Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LH8) (5.3L)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations
System Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System
Information > Service and Repair > Seat Belts
Repairs and Inspections Required After a Collision: Service and Repair Seat Belts
Repairs and Inspections Required After a Collision
Warning
Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in
need of replacement are replaced:
* Replace any seat belt system that was in use during the collision serious enough to deploy any
automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat
belt systems in use by people of adult size, but seat belt systems used to secure child restraints,
infant carriers and booster seats, including LATCH system and top tether anchorages.
* Replace any seat belt system that has torn, worn, or damaged components. This not only
includes adult seat belt systems, but built-in child restraints and LATCH system components, if any.
* Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow
tag is visible. Do not replace a seat belt if only the child seat caution label is visible.
* Replace any seat belt system if you are doubtful about its condition. This not only includes adult
seat belt systems, but built-in child restraints, LATCH system components, and any restraint
system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single
seat belt system components in vehicles that have been in a collision as described above. Always
replace the entire seat belt system with the buckle, guide and retractor assembly, which includes
the latch and webbing material.
After a minor collision where no automatic restraint device was deployed, seat belt system
replacement may not be necessary, unless some of the parts are torn, worn, or damaged.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System
Information > Service and Repair > Seat Belts > Page 8842
Repairs and Inspections Required After a Collision: Service and Repair Supplemental Inflatable
Restraints
Repairs and Inspections Required After a Collision
Accident With or Without Inflator Module Deployment - Component Inspections
Warning
Proper operation of the SIR sensing system requires that any repairs to the vehicle structure return
the vehicle structure to the original production configuration. Not properly repairing the vehicle
structure could cause non-deployment in a collision or deployment for conditions less severe than
intended.
After any collision, inspect the following components as indicated. If you detect any damage,
replace the component. If you detect any damage to the mounting points or mounting hardware,
repair or replace the mounting points and mounting hardware as needed.
* The steering column-Perform the steering column accident damage checking procedures. Refer
to Steering Column Accident Damage Inspection (See: Steering and Suspension/Steering/Steering
Column/Testing and Inspection/Initial Inspection and Diagnostic Overview/Steering Column
Accident Damage Inspection).
* The instrument panel (I/P) knee bolsters and mounting points-Inspect the knee bolsters for
bending, twisting, buckling, or any other type of damage.
* The I/P brackets, braces, etc.-Inspect for bending, twisting, buckling, or any other type of
damage.
* The seat belts-Perform the seat belt operational and functional checks.
* The I/P mounting points and brackets-Inspect for bending, twisting, buckling, or any other type of
damage.
* The roof rail and roof rail module mounting points-Inspect for bending, twisting, buckling, or any
other type of damage.
* The seats and seat mounting points-Inspect for bending, twisting, buckling, or any other type of
damage.
* Passenger seat bottom equipped with Passenger Presence System (PPS)-Check for any DTCs
or problems that may cause the PPS not to function properly.
Accident With Frontal Air Bag Deployment - Component Replacement and Inspections
After a collision involving air bag deployment, replace the following components. If you detect any
damage, replace the component. If you detect any damage to the mounting points or mounting
hardware, repair or replace the mounting points and mounting hardware as needed.
Note: The front passenger seat is equipped with a PPS, which detects an occupant. If the
requirements for disabling the I/P air bag are met then the PPS will communicate with the SDM to
disable/turn off the I/P air bag, even in a accident. For more information on the PPS refer to SIR
System Description and Operation (See: Air Bag Systems/Description and Operation).
* Inflatable restraint front end sensors
* Inflatable restraint I/P module, if deployed and after performing the necessary inspections listed
above
* Inflatable restraint sensing and diagnostic module (SDM)
* Inflatable restraint steering wheel module
* Inflatable restraint steering wheel module coil
* Seat belt pretensioners
Perform additional inspections on the following components:
* Steering wheel module coil and the coil wiring pigtail-Inspect for melting, scorching, or other
damage due to excessive heat.
* Mounting points or mounting hardware for the I/P module, steering wheel module, SDM, front end
sensors, seat belt pretensioners, and vehicle rollover sensor-Inspect for any damage and repair or
replace each component as needed.
* Passenger Presence System (PPS) for damage to the wiring or pressure system
Accident With Side Air Bag Deployment - Component Replacement and Inspections
After a collision involving side air bag deployment, replace the following components:
* Inflatable restraint roof rail module, on the side of the impact.
* Inflatable restraint side impact sensors (SIS) (left/right), on the side of the impact
* Inflatable restraint side impact module (left/right), on the side of the impact
* Inflatable restraint SDM
* Seat belt pretensioner, on the side of impact.
Perform additional inspections on the following components:
* Mounting points or mounting hardware for the SIS, roof rail module (left/right), and seat belt
pretensioner on the side of impact-Inspect for any
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System
Information > Service and Repair > Seat Belts > Page 8843
damage and repair or replace each component as needed.
* Mounting points or mounting hardware for the SDM and vehicle rollover sensor-Inspect for any
damage and repair or replace each component as needed.
Sensor Replacement Guidelines
The SIR/side air bag sensor replacement policy requires replacing sensors in the area of accident
damage. The area of accident damage is defined as the portion of the vehicle which is crushed,
bent, or damaged due to a collision. An example of this would be a moderate collision where the
front of the vehicle impacts a tree, if the vehicle has an SIR sensor mounted forward of the radiator,
replace the SIR sensor.
* Replace the sensor whether or not the air bags have deployed.
* Replace the sensor even if the sensor appears to be undamaged.
Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the
wire insulation, can cause improper operation of the SIR/side air bag sensing system. Do not try to
determine whether the sensor is undamaged. Replace the sensor. Also, if you follow a diagnostic
trouble code (DTC) table and a malfunctioning sensor is indicated, replace the sensor.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views (See: Locations).
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Warning
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR
deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power
to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG
warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See:
Diagrams/Electrical Diagrams) or Electrical Center
Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID).
4. Wait 1 minute before working on the system.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Page 8848
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to
SIR Schematics (See: Diagrams/Electrical Diagrams) or Electrical Center Identification
Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to
Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
4. Wait 1 minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer
to Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Harness Routing Views
Air Bag: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Harness Routing Views > Page 8853
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Harness Routing Views > Page 8854
15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Harness Routing Views > Page 8855
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210
(A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control
Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to
Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Harness Routing Views > Page 8856
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Harness Routing Views > Page 8857
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Harness Routing Views > Page 8858
Air Bag: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Harness Routing Views > Page 8859
Air Bag: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Front of the Headliner Components (ASF)
1 - Inflatable Restraint Roof Rail Module - Right 2 - Windshield 3 - Inflatable Restraint Roof Rail
Module -Right Connector 4 - Inflatable Restraint Roof Rail Module - Right Connector Body Harness
Side 5 - Inflatable Restraint Roof Rail Module - Left Connector Body Harness Side 6 - Inflatable
Restraint Roof Rail Module - Left Connector 7 - Inflatable Restraint Roof Rail Module - Left
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Page 8860
Air Bag: Diagrams
Component Connector End Views
Inflatable Restraint I/P Module
Inflatable Restraint Passenger Presence System (PPS) Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Page 8861
Inflatable Restraint Roof Rail Module - Left (ASF)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Page 8862
Inflatable Restraint Roof Rail Module - Right (ASF)
Inflatable Restraint Steering Wheel Module X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Page 8863
Inflatable Restraint Steering Wheel Module X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab)
Air Bag: Service and Repair Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew
Cab)
Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab)
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair). 2. Remove the head restraints from the front seats. Refer to Front
Seat Head Restraint Replacement (See: Body and Frame/Seats/Head Rest/Service
and Repair/Front Seat Head Restraint Replacement).
3. Lower the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body
and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
4. Disconnect the roof rail air bag electrical connector (1). 5. Remove the forward tether bolt (3). 6.
Remove the clips (3) from the pillar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8866
7. Remove the 3 bolts retaining the rear curtain to the roof. 8. Remove the bolt retaining the bracket
to the roof.
9. Remove the forward curtain clip (2).
10. Remove the 3 bolts (1, 3) retaining the air bag module to the roof. 11. Remove the roof rail air
bag from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8867
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the 3 bolts (1, 3) retaining the roof rail air bag module to the roof.
Tighten the roof rail air bag module bolts to 9 Nm (79 lb in).
2. Install the forward curtain clip (2). 3. Install the bolt retaining the bracket to the roof.
4. Install the 3 bolts retaining the rear curtain to the roof.
Tighten the roof rail air bag curtain bolts to 9 Nm (79 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8868
5. Install the clips (3) to the pillar. 6. Install the roof rail air bag forward tether bolt (3).
Tighten the roof rail air bag forward tether bolt to 9 Nm (79 lb in).
7. Connect the roof rail air bag electrical connector (1). 8. Install the headliner. Refer to Headlining
Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
9. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
10. Install the head restraints from the front seats. Refer to Front Seat Head Restraint Replacement
(See: Body and Frame/Seats/Head Rest/Service
and Repair/Front Seat Head Restraint Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8869
Air Bag: Service and Repair Inflatable Restraint Roof Side Rail Module Replacement - Front
(Regular and Extended Cab)
Inflatable Restraint Roof Side Rail Module Replacement - Front (Regular and Extended Cab)
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair). 2. Remove the head restraints from the front seats. Refer to Front
Seat Head Restraint Replacement (See: Body and Frame/Seats/Head Rest/Service
and Repair/Front Seat Head Restraint Replacement).
3. Lower the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body
and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
4. Disconnect the roof rail air bag electrical connector (1). 5. Remove the forward tether bolt (3). 6.
Remove the clips (3) from the pillar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8870
7. Remove the forward curtain clip (2). 8. Remove the 3 bolts (1) retaining the air bag module to the
roof. 9. Remove the bolt (5) retaining the rear curtain to the roof.
10. Remove the rear tether bolt (3). 11. Remove the roof rail air bag from the vehicle.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the 3 bolts (1) retaining the roof rail air bag module to the roof.
Tighten the roof rail air bag module bolts to 9 Nm (79 lb in).
2. Install a new forward curtain clip (2). 3. Install the bolt (5) retaining the rear curtain to the roof.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8871
Tighten the roof rail air bag curtain bolts to 9 Nm (79 lb in).
4. Install the rear tether bolt (3).
Tighten the roof rail air bag rear tether bolt to 9 Nm (79 lb in).
5. Install the clips (3) to the pillar. 6. Install the roof rail air bag forward tether bolt (3).
Tighten the roof rail air bag forward tether bolt to 9 Nm (79 lb in).
7. Connect the roof rail air bag electrical connector (1). 8. Install the headliner. Refer to Headlining
Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
9. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
10. Install the head restraints from the front seats. Refer to Front Seat Head Restraint Replacement
(See: Body and Frame/Seats/Head Rest/Service
and Repair/Front Seat Head Restraint Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Air Bag: Service and Repair Inflatable Restraint Steering Wheel Module Replacement
Steering Wheel Inflatable Restraint Module Replacement
Removal Procedure
Warning: Refer to SIR Inflator Module Handling and Storage Warning (See: Service
Precautions/SIR Inflator Module Handling and Storage Warning).
Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning).
1. Disable the inflatable restraint steering wheel module. Refer to SIR Disabling and Enabling (See:
Air Bag(s) Arming and Disarming/Service and
Repair).
2. Locate the access holes (1) positioned on both sides of the steering wheel shroud.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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3. Using a 5.5 mm or 1/4 inch socket with a long 1/4 inch drive handle, push the leaf spring
fasteners (1) inward through the access holes.
4. Lift and partially remove the inflatable restraint steering wheel module from the steering wheel in
order to expose the electrical connectors. 5. Disconnect the electrical connectors (1). 6. Disconnect
the horn electrical connector (3).
Note: Do not attempt to repair the inflatable restraint steering wheel module. The inflatable restraint
steering wheel module is replaced only as an assembly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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7. Remove the inflatable restraint module from the steering wheel. 8. Fully deploy the module
before disposal. If the module was replaced under warranty, fully deploy and dispose of the module
after the required
retention period. Refer to Inflator Module Handling and Scrapping (See: ).
Installation Procedure
1. Position the inflatable restraint module to the steering wheel. 2. Connect the electrical
connectors (1) to the inflatable restraint steering wheel module. 3. Connect the horn electrical
connector (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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4. Position the 4 alignment posts of the inflatable restraint module to the holes that are located on
the steering wheel housing. 5. Push the inflatable restraint module into the steering wheel to
engage and latch the leaf spring fasteners (1). 6. After installation, pull up on the sides of the
inflatable restraint module to ensure the leaf spring fasteners are engaged. 7. Enable the inflatable
restraint steering wheel module. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8876
Air Bag: Service and Repair Inflator Module Handling and Scrapping
Inflator Module Handling and Scrapping
Live and Undeployed Inflator Module
Special Tools
* J 38826 SIR Deployment Harness
* J 39401-B SIR Deployment Fixture
* An appropriate pigtail adapter
Warning: Refer to SIR Inflator Module Handling and Storage Warning (See: Service
Precautions/SIR Inflator Module Handling and Storage Warning).
Take special care when handling or storing an undeployed inflator module. An inflator module
deployment produces a rapid generation of gas. This may cause the inflator module, or an object in
front of the inflator module, to project through the air in the event of an unlikely deployment.
Dual Stage Inflator Module
Dual stage inflator modules have two deployment stages. If stage 1 was used to deploy a dual
stage inflator module, stage 2 may still be active. Therefore, a deployed dual stage inflator module
must be treated as an active module. If disposal of a dual stage module is required, both
deployment loops must be energized to deploy the air bag.
Scrapping Procedure
During the course of a vehicle's useful life, certain situations may arise which will require the
disposal of a live and undeployed inflator module. Do NOT dispose a live and undeployed inflator
module through normal disposal channels until the inflator module has been deployed.
Do not deploy the inflator module in the following situations:
* After replacement of an inflator module under warranty, the inflator module may need to be
returned undeployed to the manufacturer.
* If the vehicle is the subject of a Product Liability report, GM-1241, related to the SIR system and
is subject to a preliminary investigation, do NOT alter the SIR system in any manner.
* If the vehicle is involved in a campaign affecting the inflator modules, follow the instructions in the
Campaign Service Bulletin for proper SIR handling procedures.
Deployment Procedures
You can deploy the inflator module either inside or outside of the vehicle. The method used
depends upon the final disposition of the vehicle. Review the following procedures in order to
determine which will work best in a given situation:
Deployment Outside Vehicle - Steering Wheel Module, I/P Module, and Roof Rail Module
Deploy the inflator module outside of the vehicle when the vehicle will be returned to service.
Situations that require deployment outside of the vehicle include the following:
* Using the SIR diagnostics, you determine that the inflator module is malfunctioning.
* The inflator module is cosmetically damaged, scratched, or ripped.
* The inflator module pigtail is damaged.
* The inflator module connector is damaged.
* The inflator module connector terminals are damaged.
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Deployment and disposal of a malfunctioning inflator module is subject to any required retention
period.
Warning
In order to prevent accidental deployment and the risk of personal injury, do not dispose of an
undeployed inflator module as normal shop waste. Undeployed inflator modules contain
substances that could cause severe illness or personal injury if their sealed containers are
damaged during disposal. Use the following deployment procedures to safely dispose of an
undeployed inflator module. Failure to observe the following disposal methods may be a violation of
federal, state, or local laws.
1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the
inflator module.
* If you are removing the steering wheel module, refer to Steering Wheel Inflatable Restraint
Module Replacement (See: ).
* If you are removing the I/P module, refer to Instrument Panel Inflatable Restraint Module
Replacement (See: ).
* If you are removing a roof rail module, refer to Inflatable Restraint Roof Side Rail Module
Replacement - Front (Crew Cab) (See: )Inflatable Restraint Roof Side Rail Module Replacement Front (Regular and Extended Cab) (See: ).
Warning: Refer to SIR Inflator Module Handling and Storage Warning (See: Service
Precautions/SIR Inflator Module Handling and Storage Warning).
5. Place the inflator module on a work bench, with the vinyl trim cover facing up and away from the
surface.
6. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the inflator module
or deployment fixture. If possible, use a paved,
outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Ensure
you have sufficient ventilation.
7. Clear the area of loose or flammable objects.
Note: Dual stage deployments are only used in steering wheel and I/P inflator modules. If stage 1
was used to deploy a dual stage inflator module, stage 2 may still be active. If disposal of a dual
stage module is required, both deployment loops must be energized to deploy the air bag.
8. If you are deploying a steering wheel inflator module, place the inflator module in the center of
the space.
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9. When deploying an I/P inflator module, perform the following instructions:
1. Place the J 39401-B in the center of the cleared area. 2. Fill the deployment fixture with water or
sand. 3. Using the proper nuts and bolts, mount the I/P module (1) to the deployment fixture (2),
with the vinyl trim facing up. 4. Securely tighten all fasteners that hold the I/P module (1) to the
deployment fixture (2).
10. When deploying a roof rail module, perform the following instructions:
1. Place the J 39401-B (3) in the center of the cleared area. 2. Fill the deployment fixture with water
or sand to provide sufficient stabilization of fixture during deployment. 3. Adjust and secure the
fixture arms (4) to the deployment fixture (3), using the proper nuts and bolts. 4. Attach the roof rail
module in the deployment fixture and securely tighten all fasteners.
11. Inspect the SIR deployment harness and the appropriate pigtail adapter (2) for damage.
Replace as needed. 12. Short the 2 SIR deployment harness leads (1) together using one banana
plug seated into the other. 13. Connect the appropriate pigtail adapter (2) to the SIR deployment
harness (1).
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14. Extend the SIR deployment harness and adapter to the full length from the deployment fixture
or area.
Note: On a dual stage inflator module, both connectors must be attached to the deployment
harness adapter. This will ensure that both stage 1 and stage 2 of the deployment loops are
energized, regardless of the deployment state.
15. Connect the inflator module (1) to the adapter (2) on the SIR deployment harness (3).
Note: *
The rapid expansion of gas involved with deploying an inflator module is very loud. Notify all the
people in the immediate area that you intend to deploy the inflator module.
* When the inflator module deploys, the deployment fixture may jump about 30 cm (1 ft) vertically.
This is a normal reaction of the inflator module due to the force of the rapid expansion of gas inside
the inflator module.
* If you are deploying a dual stage inflator module with stage 1 already deployed, the fixture may
not move and the noise may have been reduced.
16. Clear the area of people.
17. Separate the 2 banana plugs on the SIR deployment harness that were shorted together earlier
in the procedure.
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18. Place a 12-volt minimum/2-amp minimum power source, such as a vehicle battery, near the
shorted end of the harness. 19. Connect the SIR deployment harness wires to the power source.
Deployment of the inflator module will occur when contact is made.
20. Disconnect the SIR deployment harness from the power source after the inflator module
deploys. 21. If the inflator module did not deploy, disconnect the adapter and discontinue the
procedure and contact the Technical Assistance Group.
If deployment was successful, proceed to the following steps.
Warning
After deployment, the metal surfaces of the SIR component may be very hot. To help avoid a fire or
personal injury:
* Allow sufficient time for cooling before touching any metal surface of the SIR component.
* Do not place the deployed SIR component near any flammable objects.
22. Seat one banana plug into the other in order to short the deployment harness leads.
23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the inflator module as
soon as possible. 25. Inspect the pigtail adapter and the SIR deployment harness. Replace as
needed. 26. Dispose of the deployed inflator module through normal refuse channels. 27. Wash
your hands with a mild soap.
Deployment Inside Vehicle - Vehicle Scrapping Procedure
Deploy the inflator modules inside of the vehicle when destroying the vehicle or when salvaging the
vehicle for parts. This includes, but is not limited to, the following situations:
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* The vehicle has completed all useful life.
* Irreparable damage occurred to the vehicle in a non-deployment type accident.
* Irreparable damage occurred to the vehicle during a theft.
* The vehicle is being salvaged for parts to be used on a vehicle with a different VIN, as opposed to
rebuilding as the same VIN.
Warning
When deploying a SIR component for disposal, perform the deployment procedures in the order
listed. Failure to observe the procedures in the order listed may result in personal injury.
1. Lower the driver and passenger windows. 2. Turn the ignition switch to the OFF position and
remove the ignition key. 3. Check that all inflator modules which will be deployed are mounted
securely.
* Driver inflator module is secured to the steering wheel.
* Passenger inflator module is secured to the instrument panel.
* Left roof rail inflator module is secured to the left roof rail.
* Right roof rail inflator module is secured to the right roof rail.
4. Put on safety glasses. 5. Remove all loose objects from the front seats.
Warning
A deployed dual stage inflator module will look the same whether one or both stages were used.
Always assume a deployed dual stage inflator module has an active stage 2. Improper handling or
servicing can activate the inflator module and cause personal injury.
6. Disconnect the steering wheel module yellow connector (1) from vehicle harness yellow
connector (2).
Note: If the vehicle is equipped with dual stage air bags the steering wheel module and I/P module
will each have 4 wires. Refer to Component Connector End Views (See: Diagrams/Connector
Views) for determining high and low circuits.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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7. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the
connector. 8. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
9. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. Use
these wires to fabricate the driver deployment
harness.
10. Strip 13 mm (0.5 in) of insulation from both ends of the wires. 11. Twist together one end from
each of the wires in order to short the wires. Deployment wires shall remain shorted, and not
connected to a power
source until you are ready to deploy the inflator module.
12. Twist together the 2 connector wire leads from the high circuits from both stages of the steering
wheel module, to one set of deployment wires.
Refer to Component Connector End Views (See: Diagrams/Connector Views) in order to determine
the correct circuits.
13. Inspect that the 3-wire connection is secure.
14. Bend flat the twisted connection.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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15. Secure and insulate the 3-wire connection to the deployment harness using electrical tape.
16. Twist together the 2 connector wire leads from the low circuits from both stages of the steering
wheel module, to one set of deployment wires.
Refer to Component Connector End Views (See: Diagrams/Connector Views) in order to determine
the correct circuits.
17. Inspect that the 3-wire connection is secure.
18. Bend flat the twisted connection.
19. Secure and insulate the 3-wire connection to the deployment harness using electrical tape. 20.
Connect the deployment harness to the connector on the steering wheel module.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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21. Route the deployment harness out of the driver side of the vehicle.
22. Disconnect the yellow left roof rail harness connector from the vehicle harness connector.
23. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the
connector. 24. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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25. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire.
These wires will be used to fabricate the roof rail air
bag deployment harness.
26. Strip 13 mm (0.5 in) of insulation from both ends of the wires. 27. Twist together one end from
each of the wires in order to short the wires.
28. Twist together one connector wire lead to one deployment wire.
29. Bend flat the twisted connection. 30. Secure and insulate the connection using electrical tape.
31. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment
wire. 32. Connect the deployment harness to the yellow connector of the roof rail module.
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33. Route the deployment harness out of the driver side of the vehicle.
34. Disconnect the I/P module yellow harness connector (1) from the vehicle harness connector
(2).
Note: If the vehicle is equipped with dual stage air bags the steering wheel module and I/P module
will each have 4 wires. Refer to Component Connector End Views (See: Diagrams/Connector
Views) for determining high and low circuits.
35. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the
connector. 36. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
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37. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire.
These wires will be used to fabricate the passenger
deployment harness.
38. Strip 13 mm (0.5 in) of insulation from both ends of the wires. 39. Twist together one end from
each of the wires in order to short the wires.
40. Twist together the 2 connector wire leads from the high circuits from both stages of the I/P
module to one set of deployment wires. Refer to
Component Connector End Views (See: Diagrams/Connector Views) in order to determine the
correct circuits.
41. Inspect that the 3-wire connection is secure.
42. Bend flat the twisted connection.
43. Secure and insulate the 3-wire connection to the deployment harness using electrical tape.
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44. Twist together the 2 connector wire leads from the low circuits from both stages of the I/P
module to one set of deployment wires. Refer to
Component Connector End Views (See: Diagrams/Connector Views) in order to determine the
correct circuits.
45. Inspect that the 3-wire connection is secure.
46. Bend flat the twisted connection.
47. Secure and insulate the 3-wire connection to the deployment harness using electrical tape. 48.
Connect the deployment harness to the I/P module in-line connector.
49. Route the deployment harness out of the passenger side of the vehicle.
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50. Disconnect the yellow harness connector to the right roof rail air bag from the vehicle harness
connector.
51. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the
connector. 52. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
53. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire.
These wires will be used to fabricate the roof rail
module deployment harness.
54. Strip 13 mm (0.5 in) of insulation from both ends of the wires. 55. Twist together one end from
each of the wires in order to short the wires.
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56. Twist together one connector wire lead to one deployment wire.
57. Bend flat the twisted connection. 58. Secure and insulate the connection using electrical tape.
59. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment
wire.
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60. Connect the deployment harness to the roof rail module yellow connector.
61. Route the deployment harness out of the passenger side of the vehicle. 62. Completely cover
the windshield and the front door window openings with a drop cloth. 63. Stretch to the full length
all of the deployment harness wires on the right side of the vehicle. 64. Deploy each deployment
loop one at a time. 65. Place a power source, 12 V minimum / 2 A minimum, such as a vehicle
battery, near the shorted end of the harnesses. 66. Separate one set of wires and touch the wire
ends to the power source in order to deploy the selected inflator module. 67. Disconnect the
deployment harness from the power source and twist the wire ends together. 68. Continue the
same process with the remaining deployment harnesses.
69. Stretch to the full length all of the deployment harness wires on the left side of the vehicle. 70.
Deploy each deployment loop one at a time. 71. Place a power source, 12 V minimum / 2 A
minimum, such as a vehicle battery, near the shorted end of the harnesses. 72. Separate one set
of wires and touch the wires ends to the power source in order to deploy the selected inflator
modules.
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73. Disconnect the deployment harness from the power source and twist the wire ends together.
74. Continue the same process with the remaining deployment harnesses. 75. Remove the drop
cloth from the vehicle. 76. Disconnect all harnesses from the vehicle. 77. Discard the harnesses.
78. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 79. If one or all of the
inflator modules did not deploy, perform the following steps to remove the undeployed modules
from the vehicle:
* Steering Wheel Inflatable Restraint Module Replacement (See: )
* Instrument Panel Inflatable Restraint Module Replacement (See: )
* Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) (See: )Inflatable
Restraint Roof Side Rail Module Replacement - Front (Regular and Extended Cab) (See: )
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Air Bag: Service and Repair Instrument Panel Inflatable Restraint Module Replacement
Instrument Panel Inflatable Restraint Module Replacement
Removal Procedure
Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning).
Warning: Refer to SIR Inflator Module Handling and Storage Warning (See: Service
Precautions/SIR Inflator Module Handling and Storage Warning).
1. Disable the SIR System. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair). 2. Remove the instrument panel (I/P) accessory trim panel. Refer
to Instrument Panel Accessory Trim Plate Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair).
3. Remove the radio. Refer to Radio Replacement (See: Accessories and Optional
Equipment/Radio, Stereo, and Compact
Disc/Radio/Stereo/Service and Repair/Radio Replacement).
4. Remove the right access cover from the I/P end cap. 5. Remove the right air outlet. Refer to
Instrument Panel Outer Air Outlet Replacement - Right Side (See: Heating and Air Conditioning/Air
Register/Service and Repair/Instrument Panel Outer Air Outlet Replacement - Right Side).
6. Remove the I/P compartment door. Refer to Instrument Panel Compartment Door Replacement
(See: Body and Frame/Interior Moulding /
Trim/Glove Compartment/Service and Repair).
7. Remove the digital radio receiver, if equipped. Refer to Digital Radio Receiver Replacement
(See: Accessories and Optional Equipment/Radio,
Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Digital Radio Receiver Replacement).
8. Access the 2 fasteners located above the service holes (1) inside the I/P compartment door
opening.
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9. Remove the fasteners from the passenger supplemental inflatable restraint (PSIR) inflator
module.
10. Remove the 2 side retaining nuts (1) from the PSIR module.
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11. Partially remove the PSIR inflator module from the I/P. 12. Disconnect the connector position
assurance (CPA). 13. Disconnect the electrical connector from the PSIR module. 14. Remove the
PSIR inflator module from the vehicle. 15. Fully deploy the module before disposal. If the module is
being replaced under warranty, fully deploy and dispose of the module after the required
retention period. Refer to Inflator Module Handling and Scrapping (See: ).
Note: If the PSIR module has deployed while attached to the I/P, the PSIR bracket MUST be
replaced.
16. If replacing the PSIR bracket, remove the I/P assembly. Refer to Instrument Panel Assembly
Replacement (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair).
17. Remove the 2 fasteners retaining the PSIR bracket to the I/P structure.
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18. Remove the PSIR bracket from the vehicle.
Installation Procedure
1. If replacing the PSIR bracket, install the PSIR bracket to the I/P structure.
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Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the 2 fasteners retaining the PSIR bracket to the I/P structure.
Tighten the fasteners to 9 Nm (80 lb in).
3. Install the I/P assembly. Refer to Instrument Panel Assembly Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair).
4. Position the PSIR inflator module to the front of the I/P and connect the electrical connector. 5.
Connect the CPA. 6. Install the PSIR inflator module to the I/P.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8898
7. Partially Install the 2 lower fasteners retaining the PSIR module to the I/P structure.
8. Install the 2 side retaining nuts (1) to the PSIR inflator module.
Tighten the 4 PSIR fasteners until fully driven, seated and not stripped.
9. Install the digital radio receiver, if equipped. Refer to Digital Radio Receiver Replacement (See:
Accessories and Optional Equipment/Radio,
Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Digital Radio Receiver Replacement).
10. Install the radio. Refer to Radio Replacement (See: Accessories and Optional
Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service
and Repair/Radio Replacement).
11. Install the I/P accessory trim panel. Refer to Instrument Panel Accessory Trim Plate
Replacement (See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
12. Install the right air outlet. Refer to Instrument Panel Outer Air Outlet Replacement - Right Side
(See: Heating and Air Conditioning/Air
Register/Service and Repair/Instrument Panel Outer Air Outlet Replacement - Right Side).
13. Install the right access cover to the I/P end cap. 14. Enable the SIR System. Refer to SIR
Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 15. Install the
I/P compartment door. Refer to Instrument Panel Compartment Door Replacement (See: Body and
Frame/Interior Moulding /
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8899
Trim/Glove Compartment/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Relay > Component Information >
Locations
Air Bag Relay: Locations
Component Connector End Views
Relay Inflatable Restraint
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations
Air Bag Control Module: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8906
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8907
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8908
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8909
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8910
Air Bag Control Module: Diagrams
Component Connector End Views
Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8911
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8912
Air Bag Control Module: Service and Repair
Inflatable Restraint Sensing and Diagnostic Module Replacement
Removal Procedure
Warning
Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying
power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of
the vehicle. Failure to observe the correct installation procedure could cause SIR deployment,
personal injury, or unnecessary SIR system repairs.
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair). 2. Remove the floor console. Refer to Console Replacement
(Large w/Manual or Auto Transmission) (See: Body and Frame/Interior Moulding /
Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See:
Body and Frame/Interior Moulding / Trim/Console/Service and Repair).
3. Cut the carpet along the "I" cut pattern over the inflatable restraint sensing and diagnostic
module (SDM). 4. Fold the carpet back to expose the SDM.
5. Disconnect the electrical connector (2) from the SDM (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8913
6. Remove the nuts (2) retaining the SDM (1) to the floor studs (3). 7. Remove the SDM from the
vehicle.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the SDM (1) to the floor studs (3) with 3 nuts (2).
Tighten the SDM nuts to 9 Nm (79 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8914
2. Connect the electrical connector (2) to the SDM (1). 3. Fold the carpet back down over the SDM.
4. Install the floor console. Refer to Console Replacement (Large w/Manual or Auto Transmission)
(See: Body and Frame/Interior Moulding /
Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See:
Body and Frame/Interior Moulding / Trim/Console/Service and Repair).
Note: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may
set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after
enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to
ensure that the SDM is set properly.
5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair). 6. Program the SDM. Refer to Control Module References (See:
Testing and Inspection/Programming and Relearning).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > Procedures
Clockspring Assembly / Spiral Cable: Procedures
Inflatable Restraint Steering Wheel Module Coil Centering
Caution: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly
may damage the unit, causing an inflatable restraint malfunction.
Note: If double wire harness strap is installed onto the wire harness assembly and column, you
must reuse the holder for the wire straps during installation.
Remove the wire harness strap(s) where necessary.
1. Verify the following conditions before centering the SIR coil:
* The wheels on the vehicle are straight ahead.
* The block tooth (1) of the steering shaft assembly is in the 12 o'clock position.
* The ignition switch is in the LOCK position.
2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring
service lock (1), perform the following steps:
1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub
clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the
centering window appears yellow and both arrows (3) line up. 4. Release spring service lock
between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn
tower and slide onto the steering shaft assembly.
3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO
spring service lock, perform the following steps:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > Procedures > Page 8919
1. Hold the SIR coil with the face up. 2. Rotate the coil hub clockwise until the coil ribbon stops. 3.
Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both
arrows (2) line up. This is the CENTER
position.
4. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and
slide onto the steering shaft assembly.
4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a
spring service lock (1), perform the following steps:
1. Hold the SIR coil with the back side up. 2. While depressing the spring service lock, rotate the
coil hub in the direction of the arrow (4) until the coil ribbon stops. 3. Still pressing the spring
service lock, rotate the coil hub in the opposite direction 21/2 revolutions. 4. Release the spring
service lock between locking tabs. The SIR coil is now centered. 5. Align the centered SIR coil with
the horn tower and slide onto the steering shaft assembly.
5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO
spring service lock, perform the following steps:
1. Hold the SIR coil with the face up. 2. Rotate the coil hub in the direction of the arrow until the coil
ribbon stops. 3. Rotate the coil hub, slowly, counterclockwise, for 21/2 revolutions. This is the
CENTER position. 4. While maintaining the coil hub in the CENTER position, align the centered
SIR coil with the horn tower and slide onto the steering shaft
assembly.
6. If double wire harness strap is installed onto the wire harness assembly and column, you must
route the wires up against the steering column. One
wire harness strap will surround one lead from the coil to the steering column. The other wire
harness strap will surround all leads to the steering column.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > Procedures > Page 8920
Clockspring Assembly / Spiral Cable: Removal and Replacement
Steering Wheel Inflatable Restraint Module Coil Replacement
Removal Procedure
Note: The inflatable restraint steering wheel module coil and the multifunction turn signal switch are
serviced as an assembly.
Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning).
1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling
(See: Air Bag(s) Arming and Disarming/Service
and Repair).
2. Remove the steering wheel. Refer to Steering Wheel Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and
Repair/Steering Wheel Replacement).
3. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
4. Remove the wire harness straps from the wire harness assembly. 5. Disconnect any electrical
connectors as needed.
6. Remove the inflatable restraint steering wheel module coil bolts. 7. Slide the inflatable restraint
steering wheel module coil off of the steering column. Discard the inflatable restraint steering wheel
module coil, if
replacing.
Installation Procedure
Note: A new inflatable restraint steering wheel module coil will come precentered with a centering
tab attached. Do NOT remove the centering tab until installation is complete. Failure to follow
procedure will cause a misalignment and re-centering of the inflatable restraint steering wheel
module coil will be required.
If reusing the existing inflatable restraint steering wheel module coil, you must center the inflatable
restraint steering wheel module coil. Refer to Inflatable Restraint Steering Wheel Module Coil
Centering (See: Procedures).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > Procedures > Page 8921
1. Slide the inflatable restraint steering wheel module coil onto the steering column.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the inflatable restraint steering wheel module coil bolts.
Tighten the bolts to 4.5 Nm (40 lb in).
3. Route the wiring harness assembly down the steering column. 4. Connect any electrical
connectors as needed. 5. Install the wire harness straps to the wire harness assembly. 6. Remove
the centering tab from the inflatable restraint steering wheel module coil, if equipped. 7. Install the
steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering
and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
8. Install the steering wheel. Refer to Steering Wheel Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and
Repair/Steering Wheel Replacement).
9. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Door Component Views
Impact Sensor: Locations Door Component Views
Door Component Views
Driver Door Components
1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker
- Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch
(DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF)
Front Passenger Door Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Door Component Views > Page 8926
1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door
Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Door Component Views > Page 8927
Impact Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Front of the Engine Compartment Components
1 - Ambient Air Temperature (AAT) Sensor (DF8) 2 - Horn Assembly 3 - Inflatable Restraint Front
End Sensor - Left 4 - Inflatable Restraint Front End Sensor - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Door Component Views > Page 8928
Impact Sensor: Locations Harness Routing Views
Harness Routing Views
Forward Lamp Harness Routing
1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn
Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right
11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low
Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body
Harness) 16 - X103 (Forward Lamp Harness to Body Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Door Component Views > Page 8929
17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness
(TT5) 19 - Forward Lamp Harness (-TT5)
Driver Door Harness Routing
1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside
Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body
Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver
Front Passenger Door Harness Routing
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Door Component Views > Page 8930
1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front
Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body
Harness) 9 - X210 (Body Harness to Front Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Page 8931
Impact Sensor: Diagrams
Component Connector End Views
Inflatable Restraint Front End Sensor - Left
Inflatable Restraint Front End Sensor - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Page 8932
Inflatable Restraint Passenger Presence System (PPS) Sensor
Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Page 8933
Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
and Repair > Inflatable Restraint Front End Sensor Replacement
Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement
Inflatable Restraint Front End Sensor Replacement
Removal Procedure
Warning
Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end
sensor make sure that it is securely fastened. Failure to observe the correct installation procedure
could cause SIR deployment, personal injury, or unnecessary SIR system repairs.
Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair). 2. Remove the grille. Refer to Grille Replacement (See: Body and
Frame/Grille/Service and Repair).
3. Loosen the fasteners (1) retaining the front discriminating sensors to the radiator support.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8936
4. Remove the sensor assembly from the radiator support.
5. Position the sensor assembly, to gain access to the electrical connector. 6. Remove the
connector-position assurance (CPA) from the sensor electrical connector. 7. Disconnect the sensor
electrical connector. 8. Remove the sensor from the vehicle.
Installation Procedure
1. Remove any dirt, grease, or other impurities from the mounting surfaces.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8937
2. Position the sensor near the radiator support. 3. Connect the sensor electrical connector. 4.
Install the CPA to the sensor electrical connector.
5. Install the sensor assembly to the radiator support.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8938
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the 2 fasteners (1) retaining the discriminating sensor assembly to the radiator support.
Tighten the bolts to 9 Nm (80 lb in).
7. Install the grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair).
8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8939
Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement
Inflatable Restraint Vehicle Rollover Sensor Replacement
Removal Procedure
Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
2. Fold back the carpet in order to gain access to the sensor. Refer to Floor Panel Carpet
Replacement (See: Body and Frame/Interior Moulding /
Trim/Carpet/Service and Repair).
3. Disconnect the electrical connector. 4. Remove the nuts securing the rollover sensor to the floor
panel.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8940
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the nuts securing the rollover sensor to the floor panel.
Tighten the screws to 10 Nm (88 lb in).
2. Connect the electrical connectors. 3. Install the carpet. Refer to Floor Panel Carpet Replacement
(See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair). 4. Enable the SIR
system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8941
Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement
Inflatable Restraint Side Impact Sensor Replacement
Removal Procedure
Warning
Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the
SIS make sure that it is securely fastened. Failure to observe the correct installation procedures
could cause SIR deployment, personal injury, or unnecessary SIR system repairs.
Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
2. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair).
3. Peel the rear half of the water deflector away from the door in order to access the side impact
sensor. 4. Remove the screws that retain the side impact sensor to the door. 5. Disconnect the
impact sensor electrical connector from the side impact sensor. 6. Remove the side impact sensor
from the door.
Installation Procedure
1. Remove any dirt, grease, or other impurities from the mounting surface.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8942
2. Position the side impact sensor horizontally to the door. 3. Connect the electrical connector to
the side impact sensor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the screws which retain the side impact sensor to the door.
Tighten the screws to 9 Nm (79 lb in).
5. Fully seat the water deflector to the door. 6. Install the door trim panel. Refer to Front Side Door
Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Panel/Service and Repair).
7. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Technical Service Bulletins > Restraints - Passenger Presence System Information
Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System
Information
INFORMATION
Bulletin No.: 06-08-50-009F
Date: December 23, 2010
Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With
Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices
Models:
2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing
System
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories).
Concerns About Safety and Alterations to the Front Passenger Seat
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT
VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY
ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN
OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF
SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED.
The front passenger seat in many GM vehicles is equipped with a passenger sensing system that
will turn off the right front passenger's frontal airbag under certain conditions, such as when an
infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the
right front passenger's seat mounted side impact airbag. For the system to function properly,
sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger
sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers,
upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by
GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an
aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or
between the occupant and the seat fabric.
Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM
ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR
SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE
APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH
IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE
NECESSARY BY SUCH USE.
Many types of aftermarket accessories are available to customers, upfitting shops, and dealers.
Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat
heaters are installed under the seat fabric. Additionally, seat covers made of leather or other
materials may have different padding thickness installed that could prevent the Passenger Sensing
System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to
the seat cushion, as this may interfere with the operation of the Passenger Sensing System and
either prevent proper deployment of the passenger airbag or prevent proper suppression of the
passenger air bag.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Technical Service Bulletins > Page 8947
Seat Occupant Sensor: Locations
Passenger Compartment/Roof Component Views
Passenger Seat Components - 2 of 2
1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence
System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Technical Service Bulletins > Page 8948
Seat Occupant Sensor: Service and Repair
Inflatable Restraint Passenger Presence System Replacement - Front
Removal Procedure
Warning
Replace the passenger presence system as a complete assembly to prevent possible injury to the
occupant. The bladder, the pressure sensor, the seat cushion, and the control module are
assembled and calibrated as a unit. Using only some of the components in the service kit will
cause the passenger presence system to operate improperly.
1. Remove the seat cushion trim cover and pad. 2. Disconnect the electrical connectors. 3.
Remove the bolts that retain the electronic control unit (ECU) (1) from the bottom of the passenger
seat cushion frame. 4. Remove the pressure switch (2) from the bottom of the passenger seat
cushion frame.
5. Remove the push-in retainers (1) that hold the bladder to the seat cushion frame. 6. Remove the
inflatable restraint passenger presence system from the seat.
Installation Procedures
1. Install the inflatable restraint passenger presence system to the seat. 2. Install the push-in
retainers (1) that hold the bladder to the seat cushion frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Technical Service Bulletins > Page 8949
3. Install the pressure sensor (2) to the bottom of the passenger seat cushion frame.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the bolts that retain the ECU (1) to the bottom the passenger seat cushion frame.
Tighten the bolts to 2 Nm (18 lb in).
5. Connect the electrical connectors. 6. Install the seat cushion trim cover and pad. 7. Re-zero the
inflatable restraint passenger presence system. Refer to Control Module References (See: Testing
and Inspection/Programming and
Relearning).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information >
Locations
Seat Position Sensor: Locations
Passenger Compartment/Roof Component Views
Under the Driver Seat Components
1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1)
5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver
Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver
Passenger Seat Components - 1 of 2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information >
Locations > Page 8953
1 - Inflatable Restraint Seat Belt Tension Sensor - Passenger 2 - Inflatable Restraint Seat Position
Sensor (SPS) - Passenger
Under the Passenger Seat Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information >
Locations > Page 8954
1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor
(SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger
(KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1)
7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information >
Locations > Page 8955
Seat Position Sensor: Diagrams
Component Connector End Views
Inflatable Restraint Seat Position Sensor - Left
Inflatable Restraint Seat Position Sensor - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information >
Locations > Page 8956
Seat Position Sensor: Service and Repair
Inflatable Restraint Seat Position Sensor Replacement (Power Seat)
Removal Procedure
1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Body and
Frame/Seats/Service and Repair/Front Seat
Replacement - Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and
Repair/Split Bench Seat Replacement).
2. Ensure that the seat is in the full rear position.
3. Locate the seat position sensor (1) under the seat on the inside of the inner seat rail. 4.
Disconnect the electrical connector (3) from the seat position sensor (1). 5. Remove the 2 nuts (2)
that retain the seat position sensor to the seat rail. 6. Remove the seat position sensor from the
seat.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information >
Locations > Page 8957
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the seat position sensor (1) to the seat rail with 2 nuts (2).
Tighten the seat position sensor nuts to 9 Nm (79 lb in).
2. Connect the electrical connector (13) to the seat position sensor (1). 3. Install the seat in the
vehicle. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and
Repair/Front Seat Replacement
- Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split
Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service
Bulletins > Restraints - Driver/Passenger Seat Head Rest Information
Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest
Information
INFORMATION
Bulletin No.: 10-08-50-003A
Date: March 24, 2011
Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom
Upholstery or Other Comfort Enhancing Devices
Models:
2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 10-08-50-003 (Section 08 - Body and Accessories).
Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE
HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS
RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD
RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED
DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE
OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS
INCURRED.
You may have a customer with a concern that the head restraint is uncomfortable or sits too far
forward. The front driver and passenger seats are equipped with head restraints that have been
designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle
has its own specifically designed head restraint.
The head restraints should only be used in the vehicle for which they were designed. The head
restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or
head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or
head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket
comfort enhancing pad or device, is installed.
Never modify the design of the head restraint or remove the head restraint from the vehicle as this
may interfere with the operation of the seating and restraint systems and may prevent proper
positioning of the passenger within the vehicle.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
Air Bag Control Module: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8966
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8967
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8968
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8969
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8970
Air Bag Control Module: Diagrams
Component Connector End Views
Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8971
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8972
Air Bag Control Module: Service and Repair
Inflatable Restraint Sensing and Diagnostic Module Replacement
Removal Procedure
Warning
Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying
power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of
the vehicle. Failure to observe the correct installation procedure could cause SIR deployment,
personal injury, or unnecessary SIR system repairs.
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s)
Arming and Disarming/Service and Repair). 2. Remove the floor console. Refer to Console
Replacement (Large w/Manual or Auto Transmission) (See: Body and Frame/Interior Moulding /
Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See:
Body and Frame/Interior Moulding / Trim/Console/Service and Repair).
3. Cut the carpet along the "I" cut pattern over the inflatable restraint sensing and diagnostic
module (SDM). 4. Fold the carpet back to expose the SDM.
5. Disconnect the electrical connector (2) from the SDM (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8973
6. Remove the nuts (2) retaining the SDM (1) to the floor studs (3). 7. Remove the SDM from the
vehicle.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the SDM (1) to the floor studs (3) with 3 nuts (2).
Tighten the SDM nuts to 9 Nm (79 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8974
2. Connect the electrical connector (2) to the SDM (1). 3. Fold the carpet back down over the SDM.
4. Install the floor console. Refer to Console Replacement (Large w/Manual or Auto Transmission)
(See: Body and Frame/Interior Moulding /
Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See:
Body and Frame/Interior Moulding / Trim/Console/Service and Repair).
Note: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may
set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after
enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to
ensure that the SDM is set properly.
5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s)
Arming and Disarming/Service and Repair). 6. Program the SDM. Refer to Control Module
References (See: Testing and Inspection/Programming and Relearning).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Relay >
Component Information > Locations
Air Bag Relay: Locations
Component Connector End Views
Relay Inflatable Restraint
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views (See: Air Bag Systems/Locations).
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Warning
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR
deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power
to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG
warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Air
Bag Systems/Diagrams/Electrical Diagrams) or
Electrical Center Identification Views (See: Maintenance/Fuses and Circuit
Breakers/Fuse/Application and ID).
4. Wait 1 minute before working on the system.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Page 8982
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to
SIR Schematics (See: Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical
Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and
ID).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to
Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
4. Wait 1 minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer
to Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 >
Recall - Child Seat Top Tether Anchor Not Accessible
Technical Service Bulletin # 10367 Date: 101206
Recall - Child Seat Top Tether Anchor Not Accessible
FMVSS NONCOMPLIANCE
Bulletin No.: 10367
Date: December 06, 2010
Subject: 10367 - Child Restraint Top Tether Anchor Not Accessible for Front Center Seating
Position
Models:
2004-2011 Chevrolet Colorado 2004-2011 GMC Canyon Regular Cab, Extended Cab without Rear
Seats Equipped with a Front 60/40 Split Bench Seat
Condition
General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC
Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a
front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard
(FMVSS) 225, (CMVSS) 210.1, Child Restraint Anchorage Systems. The child restraint top tether
anchor for the front center seat position in these vehicles is not accessible as required by the
Standard. Without the top tether anchor, the child restraint may not be properly secured. FMVSS
225 also requires that the Owner Manual includes a step-by-step procedure for attaching a child
restraint top tether to a vehicle top tether anchor.
Correction
Unsold vehicles in dealer inventory, dealers are to modify the back panel trim cover to allow access
to the top tether anchor and insert a supplement into the Owner Manual.
Sold vehicles in customer hands, dealers are to provide a supplement to the Owner Manual that
describes how to install a child restraint using a top tether in the center position. Dealers are to
modify the back panel trim cover to allow access to the top tether anchor, if requested by the
customer.
Vehicles Involved
Involved are certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab
vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench
seat.
All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate
Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to
confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is
essential to routinely verify eligibility because not all similar vehicles may be involved regardless of
description or option content.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, has been prepared and will be provided to dealers through the GM
GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved
vehicles currently assigned.
Parts Information
No parts are required for this recall.
Service Procedure
1. For vehicles in dealer inventory, proceed to Step 3 and cut a hole in the back panel trim cover to
allow access to the tether anchor. 2. For customer vehicles, provide the customer with a copy of
the letter at the back of this bulletin (customers involved in this recall did not receive a
letter) and after the customer has read the letter, ask the customer if they want this recall
performed on their vehicle. DO NOT PERFORM THIS RECALL ON CUSTOMER VEHICLES
WITHOUT THE CUSTOMER'S CONSENT.
- If the customer does NOT want this recall performed on their vehicle, place a copy of the Owner
Manual Supplement (located at the end of this service procedure) in the Owner Manual. No further
action is required. Submit a transaction using labor code T5799.
- If the customer DOES want this recall performed on their vehicle, proceed to the following step.
3. Move the driver and passenger seats to the full-forward position. 4. Remove the tether access
cover. The cover is located on the passenger side of the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 >
Recall - Child Seat Top Tether Anchor Not Accessible > Page 8992
5. Using a tape measure and pen, measure 341 mm (13 7/16 in) from the inboard side of the tether
access hole to the center of the second (center)
tether access point. Mark the center of the hole with a pen.
6. Using a tape measure and pen, measure and mark 461 mm (18 1/8 in) from the bottom of the
trim panel upward to the measurement and cross
mark the location made in Step 5.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 >
Recall - Child Seat Top Tether Anchor Not Accessible > Page 8993
Note To avoid damaging the sheet metal behind the trim panel, the drill bit must NOT extend more
than 12 mm (3/16 in) from the outside edge of the hole saw.
7. Using a 63.5 mm (2.5 in) hole saw, cut a hole in the panel to gain access to the center tether
access anchor point. Use the marks made in Steps 5
and 6 as your center point for the cut.
8. Clean the edge of the hole with a file. The actual hole will appear slightly larger than shown in
the illustration.
9. Clean the debris from the floor using a vacuum cleaner.
10. Reinstall the tether access cover over the passenger side tether access point.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 >
Recall - Child Seat Top Tether Anchor Not Accessible > Page 8994
11. Move the driver and passenger seats back to the desired position. 12. Place a copy of the
2-page Owner Manual Supplement (found below) in the Owner Manual in the glove compartment.
THIS INFORMATION IS IN ADDITION TO THE CHILD RESTRAINT INFORMATION CONTAINED
IN YOUR OWNER MANUAL
Where to Put the Restraint
According to accident statistics, children and infants are safer when properly restrained in a child
restraint system or infant restraint system secured in a rear seating position.
General Motors recommends that children and child restraints be secured in a rear seat, including:
an infant or a child riding in a rear-facing child restraint; a child riding in a forward-facing child seat;
an older child riding in a booster seat; and children, who are large enough, using safety belts.
Never put a rear-facing child seat in the front. This is because the risk to the rear-facing child is so
great, if the airbag deploys.
Warning
A child in a rear-facing child restraint can be seriously injured or killed if the right front passenger
airbag inflates. This is because the back of the rear-facing child restraint would be very close to the
inflating airbag. A child in a forward-facing child restraint can be seriously injured or killed if the
right front passenger airbag inflates and the passenger seat is in a forward position.
The vehicle may have a passenger sensing system or a manual airbag on-off switch which is
designed to turn off the right front passenger frontal airbag under certain conditions. Even if the
passenger sensing system or manual airbag on-off switch, if equipped, has turned off the right front
passenger frontal airbag, no system is fail-safe. No one can guarantee that an airbag will not
deploy under some unusual circumstance, even though it is turned off.
Secure rear-facing child restraints in a rear seat, even if the airbag is off. If you secure a
forward-facing child restraint in the right front seat, always move the front passenger seat as far
back as it will go. It is better to secure the child restraint in the back of a vehicle equipped with a
rear seat.
See "Passenger Sensing System" or "Airbag On-Off Switch" in the vehicle owner manual for
additional information.
Warning
A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags
if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a
child restraint in a rear seat.
Do not use child restraints in the center front seat position.
General Motors understands that there may be certain circumstances where it is necessary to
transport a child in a forward-facing child restraint in your vehicle. In these cases, we recommend
placing the forward-facing child restraint in the right front passenger seat where a top tether anchor
is already accessible. The vehicle may have a passenger sensing system or a manual airbag on-off
switch which is designed to turn off the right front passenger frontal airbag under certain conditions.
In addition, a forward-facing child restraint installed in the right front passenger seat would not
interact with the driver frontal airbag. Rear-facing child restraints should not be installed in vehicles
without a rear seat, even if the airbag is off. See "Child Restraints" in the vehicle owner manual for
instructions on how to install a child restraint in the right front seat position.
Securing Forward-Facing Child Restraints (Center Front Seat Position)
For vehicles without rear seats, manufacturers are required to provide top tether anchors for all
non-driver seating positions and instructions for using those anchors. Even if a top tether anchor is
available, you should not install a child restraint in the center front seating position.
Warning
A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags
if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a
child restraint in a rear seat.
In addition, some larger child restraints, if installed in the center front seating position, may interfere
with access to the driver and right front passenger safety belt buckles. See "Safety Belts" in the
vehicle owner manual for information, including warnings, about the importance of safety belt use.
If you must transport a forward-facing child restraint in the center front seat position, you must have
a hole in the back panel trim cover to allow access to the top tether anchor for that position. If your
vehicle does not already have a hole, you must have a service procedure performed on your
vehicle prior to securing a forward-facing child restraint in the center front seat position. Your GM
dealer will cut a hole into the back panel trim cover to allow access to the top tether anchor for the
front center seat position. This service procedure will be performed for you at no charge.
The lap belt would be used to secure a child restraint in this position, following the instructions that
came with the child restraint.
1. Adjust the driver seat to the desired driving position. Fold the armrest up, if equipped. Move the
passenger seat so that the seat and seatback are
aligned with the driver seat and seatback positions. See the appropriate section in the vehicle
owner manual for more information on adjusting the
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 >
Recall - Child Seat Top Tether Anchor Not Accessible > Page 8995
seat and seatback.
2. Place the child restraint on the seat. 3. If the child restraint manufacturer recommends using a
top tether anchor, attach the top tether on the child restraint to the top tether anchor on the
vehicle. Route the top tether according to the child restraint instructions and the following
instructions:
1. Route the top tether over the center seatback or folding armrest, if equipped.
2. Attach the top tether to the slots in the back panel as shown. Do not tighten the top tether at this
time.
4. Pick up the latch plate on the center position lap safety belt, and run the lap safety belt through
the restraint. The child restraint instructions will
show you how.
5. Push the latch plate into the buckle until it clicks. Position the release button on the buckle so
that the safety belt can be unbuckled. 6. Tighten the center position lap belt by pulling on the loose
end of the belt. It may be helpful to use your knee to push down on the child restraint as
you tighten the belt.
7. Tighten the top tether. Follow the child restraint manufacturer's instructions. 8. Before placing a
child in the child restraint, make sure it is securely held in place. To check, grasp the child restraint
at the safety belt path and
attempt to move it side to side and back and forth. When the child restraint is properly installed,
there should be no more than 2.5 cm (1 in) of movement.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
* The amount identified in Net Item should be the actual cost of a 2.5 in (63.5 mm) hole saw, not to
exceed $15.00 USD, $15.04 CAD.
Customer Notification
General Motors did not notify customers involved in this recall. The customer names and
addresses were not available. If a customer involved in this recall comes into your dealership,
please provide them with a copy of the customer letter included with this bulletin.
Dealer Recall Responsibility - For US (US States, Territories, and Possessions)
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a
recall of this type must be adequately repaired within a reasonable time after the customer has
tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not adequately repaired
within a reasonable time, the customer may be entitled to an identical or reasonably equivalent
vehicle at no charge or to a refund of the purchase price less a reasonable allowance for
depreciation. To avoid having to provide these burdensome remedies, every effort must be made
to promptly schedule an appointment with each customer and to repair their vehicle as soon as
possible if requested by the customer. In the recall notification letters, customers are told how to
contact the US National Highway Traffic Safety Administration if the recall is not completed within a
reasonable time.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 >
Recall - Child Seat Top Tether Anchor Not Accessible > Page 8996
This bulletin is notice to you that the new motor vehicles included in this recall may not comply with
the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal
for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable
Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles
without first performing the recall correction, your facility may be subject to a civil penalty for each
such sale.
Dealer Recall Responsibility
All unsold new vehicles in dealer's possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory are to be
contacted by the dealer. Arrangements are to be made to make the required correction according
to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin
for your use in contacting customers.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
facility for service in the future, you must take the steps necessary to be sure the recall correction
has been addressed before selling or releasing the vehicle.
Note
For involved customer vehicles that visit your dealership for service, addressing the recall
correction involves obtaining the customer's permission to perform the required repair.
Disclaimer
Owner Letter
Owner Letter
December 2010
Dear General Motors Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC
Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a
front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard
(FMVSS) 225 and (CMVSS) 210.1. The top tether anchor for the front center seat is not accessible
and the Owner Manual does not include instructions regarding how to use the top tether. As a
result, GM is conducting a recall. We apologize for this inconvenience. However, we are concerned
about your safety and continued satisfaction with our products.
Important
Your vehicle is involved in recall 10367.
This recall notice contains important information and instructions to the use of child restraints in
your vehicle.
- Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled?
The child restraint top tether anchor for the front center seat position in your vehicle is not
accessible as required by the Standard. FMVSS 225 also requires that the Owner Manual includes
a step-by-step procedure for attaching a child restraint top tether to a vehicle top tether anchor.
The top tether helps to secure a child seat. Even with the top tether, however, both the National
Highway Traffic Safety Administration and GM discourage placement of a child in a front seat. In
the event of a crash, a child in a child restraint in the front center seat position with or without a top
tether anchor restraint can be seriously injured or killed.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 >
Recall - Child Seat Top Tether Anchor Not Accessible > Page 8997
What will we do?
FMVSS 225 requires that we provide the enclosed Owner Manual Supplement that describes how
to install a child restraint using a top tether in the front center seat position; however, General
Motors does not recommend that you place a child restraint in the front center seat. A child in a
child restraint in the front center seat position can be seriously injured or killed by the frontal
airbags if they inflate.
If you must transport a child in a forward-facing child restraint in your vehicle, General Motors
recommends placing the forward-facing child restraint in the right front passenger seat where a top
tether anchor is already accessible. The vehicle may have a passenger sensing system or a
manual airbag on-off switch that is designed to turn off the right front passenger frontal airbag
under certain conditions. In addition, a forward-facing child restraint installed in the right front
passenger seat would not interact with the driver's frontal airbag. Rear-facing child restraints
should not be installed in vehicles without a rear seat, even if the passenger airbag is off. Please
refer to the appropriate section in your Owner Manual for more information.
Your GM dealer will cut a hole into the back panel trim cover to allow access to the top tether
anchor for the front center seat position. See the enclosed insert for an illustration. This service
procedure will be performed for you at no charge. Because of service scheduling requirements, it is
likely that your dealer will need your vehicle longer than the actual service correction time of
approximately 20 minutes.
What should you do?
Please place the enclosed Owner Manual Supplement in your Owner Manual in the Seats and
Restraints section for future reference.
Because a child in a child restraint in the front center seat position can be seriously injured or killed
by the frontal airbags if they inflate, GM does not recommend installing child restraints in the front
center seat position.
You should contact your GM dealer to arrange a service appointment to have an access hole cut
into the back panel trim cover as soon as possible. Until this recall can be performed on your
vehicle, a child restraint top tether cannot be attached to the top tether anchor for the front center
seat position. After this procedure has been performed by your dealer, the Owner Manual
Supplement provides a step-by-step procedure for attaching a child restraint top tether to the
vehicle top tether anchor for the front center seat position.
Do you have questions?
If you have questions or concerns that your dealer is unable to resolve, please contact the
appropriate Customer Assistance Center at the number listed below. More information about your
vehicle can be found at the Owner Center at www.gmownercenter.com.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10367
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 >
Recall - Child Restraint No Access, Front Center Seat
Technical Service Bulletin # 10407 Date: 101206
Recall - Child Restraint No Access, Front Center Seat
FMVSS NONCOMPLIANCE
Bulletin No.: 10407
Date: December 06, 2010
Subject: 10407 - Child Restraint Top Tether Anchor Not Accessible for Front Center Seating
Position
Models:
2004-2011 Chevrolet Colorado 2004-2011 GMC Canyon Regular Cab, Extended Cab without Rear
Seats Equipped with a Front 60/40 Split Bench Seat
Condition
General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC
Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a
front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard
(FMVSS) 225, (CMVSS) 210.1, Child Restraint Anchorage Systems. The child restraint top tether
anchor for the front center seat position in these vehicles is not accessible as required by the
Standard. Without the top tether anchor, the child restraint may not be properly secured. FMVSS
225 also requires that the Owner Manual includes a step-by-step procedure for attaching a child
restraint top tether to a vehicle top tether anchor.
Correction
Customers will be mailed an Owner Manual Supplement that describes how to install a child
restraint using a top tether in the center position. Dealers are to modify the back panel trim cover to
allow access to the top tether anchor, if requested by the customer.
Vehicles Involved
Involved are certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab
vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench
seat.
All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate
Vehicle History (GMVIS2) Application in the Applicable Warranties section. Dealership technicians
should always check this site to confirm vehicle involvement prior to beginning any required
inspections and/or repairs.
Parts Information
No parts are required for this recall.
Service Procedure
Note
Do NOT perform this service procedure unless the customer has requested it.
1. Move the driver and passenger seats to the full-forward position. 2. Remove the tether access
cover. The cover is located on the passenger side of the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 >
Recall - Child Restraint No Access, Front Center Seat > Page 9002
3. Using a tape measure and pen, measure 341 mm (13 7/16 in) from the inboard side of the tether
access hole to the center of the second (center)
tether access point. Mark the center of the hole with a pen.
4. Using a tape measure and pen, measure and mark 461 mm (18 1/8 in) from the bottom of the
trim panel upward to the measurement and cross
mark the location made in Step 5.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 >
Recall - Child Restraint No Access, Front Center Seat > Page 9003
Note To avoid damaging the sheet metal behind the trim panel, the drill bit must NOT extend more
than 12 mm (3/16 in) from the outside edge of the hole saw.
5. Using a 63.5 mm (2.5 in) hole saw, cut a hole in the panel to gain access to the center tether
access anchor point. Use the marks made in Steps 5
and 6 as your center point for the cut.
6. Clean the edge of the hole with a file. The actual hole will appear slightly larger than shown in
the illustration.
7. Clean the debris from the floor using a vacuum cleaner. 8. Reinstall the tether access cover over
the passenger side tether access point.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 >
Recall - Child Restraint No Access, Front Center Seat > Page 9004
9. Move the driver and passenger seats back to the desired position.
Warranty Transaction Information
Submit a transaction using the table below.
Customer Notification
General Motors will notify customers of this Noncompliance Special Coverage on their vehicles
(see copy of typical customer letter included with this bulletin - actual divisional letter may vary
slightly).
Dealer Recall Responsibility - For US (US States, Territories, and Possessions)
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a
recall of this type must be adequately repaired within a reasonable time after the customer has
tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not adequately repaired
within a reasonable time, the customer may be entitled to an identical or reasonably equivalent
vehicle at no charge or to a refund of the purchase price less a reasonable allowance for
depreciation. To avoid having to provide these burdensome remedies, every effort must be made
to promptly schedule an appointment with each customer and to repair their vehicle as soon as
possible if requested by the customer. In the recall notification letters, customers are told how to
contact the US National Highway Traffic Safety Administration if the recall is not completed within a
reasonable time.
This bulletin is notice to you that the new motor vehicles included in this recall may not comply with
the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal
for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable
Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles
without first performing the recall correction, your facility may be subject to a civil penalty for each
such sale.
Dealer Recall Responsibility - All
Dealers are to service all vehicles subject to this noncompliance special coverage at no charge to
customers, regardless of mileage, age of vehicle, or ownership, from this time forward if the
customer requests the repair.
THIS INFORMATION IS IN ADDITION TO THE CHILD RESTRAINT INFORMATION CONTAINED
IN YOUR OWNER MANUAL
Where to Put the Restraint
According to accident statistics, children and infants are safer when properly restrained in a child
restraint system or infant restraint system secured in a rear seating position.
General Motors recommends that children and child restraints be secured in a rear seat, including:
an infant or a child riding in a rear-facing child restraint; a child riding in a forward-facing child seat;
an older child riding in a booster seat; and children, who are large enough, using safety belts.
Never put a rear-facing child seat in the front. This is because the risk to the rear-facing child is so
great, if the airbag deploys.
Warning
A child in a rear-facing child restraint can be seriously injured or killed if the right front passenger
airbag inflates. This is because the back of the rear-facing child restraint would be very close to the
inflating airbag. A child in a forward-facing child restraint can be seriously injured or killed if the
right front passenger airbag inflates and the passenger seat is in a forward position.
The vehicle may have a passenger sensing system or a manual airbag on-off switch which is
designed to turn off the right front passenger frontal airbag under certain conditions. Even if the
passenger sensing system or manual airbag on-off switch, if equipped, has turned off the right front
passenger frontal airbag, no system is fail-safe. No one can guarantee that an airbag will not
deploy under some unusual circumstance, even though it is turned off.
Secure rear-facing child restraints in a rear seat, even if the airbag is off. If you secure a
forward-facing child restraint in the right front seat, always move the front passenger seat as far
back as it will go. It is better to secure the child restraint in the back of a vehicle equipped with a
rear seat.
See "Passenger Sensing System" or "Airbag On-Off Switch" in the vehicle owner manual for
additional information.
Warning
A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags
if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a
child restraint in a rear seat.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 >
Recall - Child Restraint No Access, Front Center Seat > Page 9005
Do not use child restraints in the center front seat position.
General Motors understands that there may be certain circumstances where it is necessary to
transport a child in a forward-facing child restraint in your vehicle. In these cases, we recommend
placing the forward-facing child restraint in the right front passenger seat where a top tether anchor
is already accessible. The vehicle may have a passenger sensing system or a manual airbag on-off
switch which is designed to turn off the right front passenger frontal airbag under certain conditions.
In addition, a forward-facing child restraint installed in the right front passenger seat would not
interact with the driver frontal airbag. Rear-facing child restraints should not be installed in vehicles
without a rear seat, even if the airbag is off. See "Child Restraints" in the vehicle owner manual for
instructions on how to install a child restraint in the right front seat position.
Securing Forward-Facing Child Restraints (Center Front Seat Position)
For vehicles without rear seats, manufacturers are required to provide top tether anchors for all
non-driver seating positions and instructions for using those anchors. Even if a top tether anchor is
available, you should not install a child restraint in the center front seating position.
Warning
A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags
if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a
child restraint in a rear seat.
In addition, some larger child restraints, if installed in the center front seating position, may interfere
with access to the driver and right front passenger safety belt buckles. See "Safety Belts" in the
vehicle owner manual for information, including warnings, about the importance of safety belt use.
If you must transport a forward-facing child restraint in the center front seat position, you must have
a hole in the back panel trim cover to allow access to the top tether anchor for that position. If your
vehicle does not already have a hole, you must have a service procedure performed on your
vehicle prior to securing a forward-facing child restraint in the center front seat position. Your GM
dealer will cut a hole into the back panel trim cover to allow access to the top tether anchor for the
front center seat position. This service procedure will be performed for you at no charge.
The lap belt would be used to secure a child restraint in this position, following the instructions that
came with the child restraint.
1. Adjust the driver seat to the desired driving position. Fold the armrest up, if equipped. Move the
passenger seat so that the seat and seatback are
aligned with the driver seat and seatback positions. See the appropriate section in the vehicle
owner manual for more information on adjusting the seat and seatback.
2. Place the child restraint on the seat. 3. If the child restraint manufacturer recommends using a
top tether anchor, attach the top tether on the child restraint to the top tether anchor on the
vehicle. Route the top tether according to the child restraint instructions and the following
instructions:
1. Route the top tether over the center seatback or folding armrest, if equipped.
2. Attach the top tether to the slots in the back panel as shown. Do not tighten the top tether at this
time.
4. Pick up the latch plate on the center position lap safety belt, and run the lap safety belt through
the restraint. The child restraint instructions will
show you how.
5. Push the latch plate into the buckle until it clicks. Position the release button on the buckle so
that the safety belt can be unbuckled. 6. Tighten the center position lap belt by pulling on the loose
end of the belt. It may be helpful to use your knee to push down on the child restraint as
you tighten the belt.
7. Tighten the top tether. Follow the child restraint manufacturer's instructions. 8. Before placing a
child in the child restraint, make sure it is securely held in place. To check, grasp the child restraint
at the safety belt path and
attempt to move it side to side and back and forth. When the child restraint is properly installed,
there should be no more than 2.5 cm (1 in) of movement.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 >
Recall - Child Restraint No Access, Front Center Seat > Page 9006
Disclaimer
Owner Letter
Owner Letter
December 2010
Dear General Motors Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC
Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a
front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard
(FMVSS) 225 and (CMVSS) 210.1. The top tether anchor for the front center seat is not accessible
and the Owner Manual does not include instructions regarding how to use the top tether. As a
result, GM is conducting a recall. We apologize for this inconvenience. However, we are concerned
about your safety and continued satisfaction with our products.
Important
- Your vehicle is involved in Noncompliance Special Coverage 10407.
- This notice contains important information and instructions to the use of child restraints in your
vehicle.
- Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled?
The child restraint top tether anchor for the front center seat position in your vehicle is not
accessible as required by the Standard. FMVSS 225 also requires that the Owner Manual includes
a step-by-step procedure for attaching a child restraint top tether to a vehicle top tether anchor.
The top tether helps to secure a child seat. Even with the top tether, however, both the National
Highway Traffic Safety Administration and GM discourage placement of a child in a front seat. In
the event of a crash, a child in a child restraint in the front center seat position with or without a top
tether anchor restraint can be seriously injured or killed.
What will we do?
FMVSS 225 requires that we provide the enclosed Owner Manual Supplement that describes how
to install a child restraint using a top tether in the front center seat position; however, General
Motors does not recommend that you place a child restraint in the front center seat. A child in a
child restraint in the front center seat position can be seriously injured or killed by the frontal
airbags if they inflate.
If you must transport a child in a forward-facing child restraint in your vehicle, General Motors
recommends placing the forward-facing child restraint in the right front passenger seat where a top
tether anchor is already accessible. The vehicle may have a passenger sensing system or a
manual on-off switch that is designed to turn off the right front passenger frontal airbag under
certain conditions. In addition, a forward-facing child restraint installed in the right front passenger
seat would not interact with the driver's frontal airbag. Rear-facing child restraints should not be
installed in vehicles without a rear seat, even if the passenger airbag is off. Please refer to the
appropriate section in your Owner Manual for more information.
Your GM dealer will cut a hole into the back panel trim cover to allow access to the top tether
anchor for the front center seat position. See the enclosed insert for an illustration. This service
procedure will be performed for you at no charge. Because of service scheduling requirements, it is
likely that your dealer will need your vehicle longer than the actual service correction time of
approximately 20 minutes.
What should you do?
Please place the enclosed Owner Manual Supplement in your Owner Manual in the Seats and
Restraints section for future reference.
Because a child in a child restraint in the front center seat position can be seriously injured or killed
by the frontal airbags if they inflate, GM does not recommend installing child restraints in the front
center seat position.
You should contact your GM dealer to arrange a service appointment to have an access hole cut
into the back panel trim cover as soon as possible. Until this recall can be performed on your
vehicle, a child restraint top tether cannot be attached to the top tether anchor for the front center
seat position. After
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 >
Recall - Child Restraint No Access, Front Center Seat > Page 9007
this procedure has been performed by your dealer, the Owner Manual Supplement provides a
step-by-step procedure for attaching a child restraint top tether to the vehicle top tether anchor for
the front center seat position.
Do you have questions?
If you have questions or concerns that your dealer is unable to resolve, please contact the
appropriate Customer Assistance Center at the number listed below. More information about your
vehicle can be found at the Owner Center at www.gmownercenter.com.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10407
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > NHTSA10V575000 >
Nov > 10 > Recall 10V575000: Child Restraint Non-Compliance
Child Seat Tether Attachment: Recalls Recall 10V575000: Child Restraint Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2011
GMC/Canyon 2004-2011
Isuzu/I-280/I-350 2006
Isuzu/I-290/I-370 2007-2008
MANUFACTURER: General Motors Corp.
MFR'S REPORT DATE: November 18, 2010
NHTSA CAMPAIGN ID NUMBER: 10V575000
NHTSA ACTION NUMBER: N/A
COMPONENT: Child Seat
POTENTIAL NUMBER OF UNITS AFFECTED: 192,676
SUMMARY: GM is recalling certain model year 2004-2011, Chevrolet Colorado, GMC Canyon,
model year 2006, Isuzu I-280/I-350, and model year 2007-2008, I-290/I-370, regular cab vehicles
and extended cab vehicles without a rear seat and equipped with a front 60/40 split bench seat.
These vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard No.
225, "Child Restraint Anchorage Systems." The top tether anchor for the front center seat is not
accessible and the owners manual does not include instructions regarding how to use the top
tether.
CONSEQUENCE: Both NHTSA and GM discourage placement of a child in a front seat.
Nevertheless, there are individual circumstances that may require placement of a child in a
restraint in the front center seating position of this vehicle that does not offer a rear seat. Lack of
access to the top tether anchor and a lack of instructions as to how to use it, may result in improper
installation of a child restraint. Improper installation of a child restraint can result in a reduction in
the restraint's performance in the event of a crash and an increased risk of injury or death to the
child seated in the restraint.
REMEDY: Dealers will cut a hole into the back panel trim cover to allow access to the top tether
anchor for the front center seat position and will provide supplemental information as to use in the
owner's manual. The manufacturer has not yet provided an owner notification schedule for this
campaign. Owners may contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at
1-800-255-6727 or visit GM'S website at www.gmownercenter.com.
NOTES: GM safety recall No. 10367. Owners may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible
Technical Service Bulletin # 10367 Date: 101206
Recall - Child Seat Top Tether Anchor Not Accessible
FMVSS NONCOMPLIANCE
Bulletin No.: 10367
Date: December 06, 2010
Subject: 10367 - Child Restraint Top Tether Anchor Not Accessible for Front Center Seating
Position
Models:
2004-2011 Chevrolet Colorado 2004-2011 GMC Canyon Regular Cab, Extended Cab without Rear
Seats Equipped with a Front 60/40 Split Bench Seat
Condition
General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC
Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a
front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard
(FMVSS) 225, (CMVSS) 210.1, Child Restraint Anchorage Systems. The child restraint top tether
anchor for the front center seat position in these vehicles is not accessible as required by the
Standard. Without the top tether anchor, the child restraint may not be properly secured. FMVSS
225 also requires that the Owner Manual includes a step-by-step procedure for attaching a child
restraint top tether to a vehicle top tether anchor.
Correction
Unsold vehicles in dealer inventory, dealers are to modify the back panel trim cover to allow access
to the top tether anchor and insert a supplement into the Owner Manual.
Sold vehicles in customer hands, dealers are to provide a supplement to the Owner Manual that
describes how to install a child restraint using a top tether in the center position. Dealers are to
modify the back panel trim cover to allow access to the top tether anchor, if requested by the
customer.
Vehicles Involved
Involved are certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab
vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench
seat.
All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate
Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to
confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is
essential to routinely verify eligibility because not all similar vehicles may be involved regardless of
description or option content.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, has been prepared and will be provided to dealers through the GM
GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved
vehicles currently assigned.
Parts Information
No parts are required for this recall.
Service Procedure
1. For vehicles in dealer inventory, proceed to Step 3 and cut a hole in the back panel trim cover to
allow access to the tether anchor. 2. For customer vehicles, provide the customer with a copy of
the letter at the back of this bulletin (customers involved in this recall did not receive a
letter) and after the customer has read the letter, ask the customer if they want this recall
performed on their vehicle. DO NOT PERFORM THIS RECALL ON CUSTOMER VEHICLES
WITHOUT THE CUSTOMER'S CONSENT.
- If the customer does NOT want this recall performed on their vehicle, place a copy of the Owner
Manual Supplement (located at the end of this service procedure) in the Owner Manual. No further
action is required. Submit a transaction using labor code T5799.
- If the customer DOES want this recall performed on their vehicle, proceed to the following step.
3. Move the driver and passenger seats to the full-forward position. 4. Remove the tether access
cover. The cover is located on the passenger side of the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
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5. Using a tape measure and pen, measure 341 mm (13 7/16 in) from the inboard side of the tether
access hole to the center of the second (center)
tether access point. Mark the center of the hole with a pen.
6. Using a tape measure and pen, measure and mark 461 mm (18 1/8 in) from the bottom of the
trim panel upward to the measurement and cross
mark the location made in Step 5.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 9018
Note To avoid damaging the sheet metal behind the trim panel, the drill bit must NOT extend more
than 12 mm (3/16 in) from the outside edge of the hole saw.
7. Using a 63.5 mm (2.5 in) hole saw, cut a hole in the panel to gain access to the center tether
access anchor point. Use the marks made in Steps 5
and 6 as your center point for the cut.
8. Clean the edge of the hole with a file. The actual hole will appear slightly larger than shown in
the illustration.
9. Clean the debris from the floor using a vacuum cleaner.
10. Reinstall the tether access cover over the passenger side tether access point.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 9019
11. Move the driver and passenger seats back to the desired position. 12. Place a copy of the
2-page Owner Manual Supplement (found below) in the Owner Manual in the glove compartment.
THIS INFORMATION IS IN ADDITION TO THE CHILD RESTRAINT INFORMATION CONTAINED
IN YOUR OWNER MANUAL
Where to Put the Restraint
According to accident statistics, children and infants are safer when properly restrained in a child
restraint system or infant restraint system secured in a rear seating position.
General Motors recommends that children and child restraints be secured in a rear seat, including:
an infant or a child riding in a rear-facing child restraint; a child riding in a forward-facing child seat;
an older child riding in a booster seat; and children, who are large enough, using safety belts.
Never put a rear-facing child seat in the front. This is because the risk to the rear-facing child is so
great, if the airbag deploys.
Warning
A child in a rear-facing child restraint can be seriously injured or killed if the right front passenger
airbag inflates. This is because the back of the rear-facing child restraint would be very close to the
inflating airbag. A child in a forward-facing child restraint can be seriously injured or killed if the
right front passenger airbag inflates and the passenger seat is in a forward position.
The vehicle may have a passenger sensing system or a manual airbag on-off switch which is
designed to turn off the right front passenger frontal airbag under certain conditions. Even if the
passenger sensing system or manual airbag on-off switch, if equipped, has turned off the right front
passenger frontal airbag, no system is fail-safe. No one can guarantee that an airbag will not
deploy under some unusual circumstance, even though it is turned off.
Secure rear-facing child restraints in a rear seat, even if the airbag is off. If you secure a
forward-facing child restraint in the right front seat, always move the front passenger seat as far
back as it will go. It is better to secure the child restraint in the back of a vehicle equipped with a
rear seat.
See "Passenger Sensing System" or "Airbag On-Off Switch" in the vehicle owner manual for
additional information.
Warning
A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags
if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a
child restraint in a rear seat.
Do not use child restraints in the center front seat position.
General Motors understands that there may be certain circumstances where it is necessary to
transport a child in a forward-facing child restraint in your vehicle. In these cases, we recommend
placing the forward-facing child restraint in the right front passenger seat where a top tether anchor
is already accessible. The vehicle may have a passenger sensing system or a manual airbag on-off
switch which is designed to turn off the right front passenger frontal airbag under certain conditions.
In addition, a forward-facing child restraint installed in the right front passenger seat would not
interact with the driver frontal airbag. Rear-facing child restraints should not be installed in vehicles
without a rear seat, even if the airbag is off. See "Child Restraints" in the vehicle owner manual for
instructions on how to install a child restraint in the right front seat position.
Securing Forward-Facing Child Restraints (Center Front Seat Position)
For vehicles without rear seats, manufacturers are required to provide top tether anchors for all
non-driver seating positions and instructions for using those anchors. Even if a top tether anchor is
available, you should not install a child restraint in the center front seating position.
Warning
A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags
if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a
child restraint in a rear seat.
In addition, some larger child restraints, if installed in the center front seating position, may interfere
with access to the driver and right front passenger safety belt buckles. See "Safety Belts" in the
vehicle owner manual for information, including warnings, about the importance of safety belt use.
If you must transport a forward-facing child restraint in the center front seat position, you must have
a hole in the back panel trim cover to allow access to the top tether anchor for that position. If your
vehicle does not already have a hole, you must have a service procedure performed on your
vehicle prior to securing a forward-facing child restraint in the center front seat position. Your GM
dealer will cut a hole into the back panel trim cover to allow access to the top tether anchor for the
front center seat position. This service procedure will be performed for you at no charge.
The lap belt would be used to secure a child restraint in this position, following the instructions that
came with the child restraint.
1. Adjust the driver seat to the desired driving position. Fold the armrest up, if equipped. Move the
passenger seat so that the seat and seatback are
aligned with the driver seat and seatback positions. See the appropriate section in the vehicle
owner manual for more information on adjusting the
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 9020
seat and seatback.
2. Place the child restraint on the seat. 3. If the child restraint manufacturer recommends using a
top tether anchor, attach the top tether on the child restraint to the top tether anchor on the
vehicle. Route the top tether according to the child restraint instructions and the following
instructions:
1. Route the top tether over the center seatback or folding armrest, if equipped.
2. Attach the top tether to the slots in the back panel as shown. Do not tighten the top tether at this
time.
4. Pick up the latch plate on the center position lap safety belt, and run the lap safety belt through
the restraint. The child restraint instructions will
show you how.
5. Push the latch plate into the buckle until it clicks. Position the release button on the buckle so
that the safety belt can be unbuckled. 6. Tighten the center position lap belt by pulling on the loose
end of the belt. It may be helpful to use your knee to push down on the child restraint as
you tighten the belt.
7. Tighten the top tether. Follow the child restraint manufacturer's instructions. 8. Before placing a
child in the child restraint, make sure it is securely held in place. To check, grasp the child restraint
at the safety belt path and
attempt to move it side to side and back and forth. When the child restraint is properly installed,
there should be no more than 2.5 cm (1 in) of movement.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
* The amount identified in Net Item should be the actual cost of a 2.5 in (63.5 mm) hole saw, not to
exceed $15.00 USD, $15.04 CAD.
Customer Notification
General Motors did not notify customers involved in this recall. The customer names and
addresses were not available. If a customer involved in this recall comes into your dealership,
please provide them with a copy of the customer letter included with this bulletin.
Dealer Recall Responsibility - For US (US States, Territories, and Possessions)
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a
recall of this type must be adequately repaired within a reasonable time after the customer has
tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not adequately repaired
within a reasonable time, the customer may be entitled to an identical or reasonably equivalent
vehicle at no charge or to a refund of the purchase price less a reasonable allowance for
depreciation. To avoid having to provide these burdensome remedies, every effort must be made
to promptly schedule an appointment with each customer and to repair their vehicle as soon as
possible if requested by the customer. In the recall notification letters, customers are told how to
contact the US National Highway Traffic Safety Administration if the recall is not completed within a
reasonable time.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 9021
This bulletin is notice to you that the new motor vehicles included in this recall may not comply with
the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal
for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable
Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles
without first performing the recall correction, your facility may be subject to a civil penalty for each
such sale.
Dealer Recall Responsibility
All unsold new vehicles in dealer's possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory are to be
contacted by the dealer. Arrangements are to be made to make the required correction according
to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin
for your use in contacting customers.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
facility for service in the future, you must take the steps necessary to be sure the recall correction
has been addressed before selling or releasing the vehicle.
Note
For involved customer vehicles that visit your dealership for service, addressing the recall
correction involves obtaining the customer's permission to perform the required repair.
Disclaimer
Owner Letter
Owner Letter
December 2010
Dear General Motors Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC
Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a
front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard
(FMVSS) 225 and (CMVSS) 210.1. The top tether anchor for the front center seat is not accessible
and the Owner Manual does not include instructions regarding how to use the top tether. As a
result, GM is conducting a recall. We apologize for this inconvenience. However, we are concerned
about your safety and continued satisfaction with our products.
Important
Your vehicle is involved in recall 10367.
This recall notice contains important information and instructions to the use of child restraints in
your vehicle.
- Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled?
The child restraint top tether anchor for the front center seat position in your vehicle is not
accessible as required by the Standard. FMVSS 225 also requires that the Owner Manual includes
a step-by-step procedure for attaching a child restraint top tether to a vehicle top tether anchor.
The top tether helps to secure a child seat. Even with the top tether, however, both the National
Highway Traffic Safety Administration and GM discourage placement of a child in a front seat. In
the event of a crash, a child in a child restraint in the front center seat position with or without a top
tether anchor restraint can be seriously injured or killed.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 9022
What will we do?
FMVSS 225 requires that we provide the enclosed Owner Manual Supplement that describes how
to install a child restraint using a top tether in the front center seat position; however, General
Motors does not recommend that you place a child restraint in the front center seat. A child in a
child restraint in the front center seat position can be seriously injured or killed by the frontal
airbags if they inflate.
If you must transport a child in a forward-facing child restraint in your vehicle, General Motors
recommends placing the forward-facing child restraint in the right front passenger seat where a top
tether anchor is already accessible. The vehicle may have a passenger sensing system or a
manual airbag on-off switch that is designed to turn off the right front passenger frontal airbag
under certain conditions. In addition, a forward-facing child restraint installed in the right front
passenger seat would not interact with the driver's frontal airbag. Rear-facing child restraints
should not be installed in vehicles without a rear seat, even if the passenger airbag is off. Please
refer to the appropriate section in your Owner Manual for more information.
Your GM dealer will cut a hole into the back panel trim cover to allow access to the top tether
anchor for the front center seat position. See the enclosed insert for an illustration. This service
procedure will be performed for you at no charge. Because of service scheduling requirements, it is
likely that your dealer will need your vehicle longer than the actual service correction time of
approximately 20 minutes.
What should you do?
Please place the enclosed Owner Manual Supplement in your Owner Manual in the Seats and
Restraints section for future reference.
Because a child in a child restraint in the front center seat position can be seriously injured or killed
by the frontal airbags if they inflate, GM does not recommend installing child restraints in the front
center seat position.
You should contact your GM dealer to arrange a service appointment to have an access hole cut
into the back panel trim cover as soon as possible. Until this recall can be performed on your
vehicle, a child restraint top tether cannot be attached to the top tether anchor for the front center
seat position. After this procedure has been performed by your dealer, the Owner Manual
Supplement provides a step-by-step procedure for attaching a child restraint top tether to the
vehicle top tether anchor for the front center seat position.
Do you have questions?
If you have questions or concerns that your dealer is unable to resolve, please contact the
appropriate Customer Assistance Center at the number listed below. More information about your
vehicle can be found at the Owner Center at www.gmownercenter.com.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10367
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat
Technical Service Bulletin # 10407 Date: 101206
Recall - Child Restraint No Access, Front Center Seat
FMVSS NONCOMPLIANCE
Bulletin No.: 10407
Date: December 06, 2010
Subject: 10407 - Child Restraint Top Tether Anchor Not Accessible for Front Center Seating
Position
Models:
2004-2011 Chevrolet Colorado 2004-2011 GMC Canyon Regular Cab, Extended Cab without Rear
Seats Equipped with a Front 60/40 Split Bench Seat
Condition
General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC
Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a
front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard
(FMVSS) 225, (CMVSS) 210.1, Child Restraint Anchorage Systems. The child restraint top tether
anchor for the front center seat position in these vehicles is not accessible as required by the
Standard. Without the top tether anchor, the child restraint may not be properly secured. FMVSS
225 also requires that the Owner Manual includes a step-by-step procedure for attaching a child
restraint top tether to a vehicle top tether anchor.
Correction
Customers will be mailed an Owner Manual Supplement that describes how to install a child
restraint using a top tether in the center position. Dealers are to modify the back panel trim cover to
allow access to the top tether anchor, if requested by the customer.
Vehicles Involved
Involved are certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab
vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench
seat.
All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate
Vehicle History (GMVIS2) Application in the Applicable Warranties section. Dealership technicians
should always check this site to confirm vehicle involvement prior to beginning any required
inspections and/or repairs.
Parts Information
No parts are required for this recall.
Service Procedure
Note
Do NOT perform this service procedure unless the customer has requested it.
1. Move the driver and passenger seats to the full-forward position. 2. Remove the tether access
cover. The cover is located on the passenger side of the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9027
3. Using a tape measure and pen, measure 341 mm (13 7/16 in) from the inboard side of the tether
access hole to the center of the second (center)
tether access point. Mark the center of the hole with a pen.
4. Using a tape measure and pen, measure and mark 461 mm (18 1/8 in) from the bottom of the
trim panel upward to the measurement and cross
mark the location made in Step 5.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9028
Note To avoid damaging the sheet metal behind the trim panel, the drill bit must NOT extend more
than 12 mm (3/16 in) from the outside edge of the hole saw.
5. Using a 63.5 mm (2.5 in) hole saw, cut a hole in the panel to gain access to the center tether
access anchor point. Use the marks made in Steps 5
and 6 as your center point for the cut.
6. Clean the edge of the hole with a file. The actual hole will appear slightly larger than shown in
the illustration.
7. Clean the debris from the floor using a vacuum cleaner. 8. Reinstall the tether access cover over
the passenger side tether access point.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9029
9. Move the driver and passenger seats back to the desired position.
Warranty Transaction Information
Submit a transaction using the table below.
Customer Notification
General Motors will notify customers of this Noncompliance Special Coverage on their vehicles
(see copy of typical customer letter included with this bulletin - actual divisional letter may vary
slightly).
Dealer Recall Responsibility - For US (US States, Territories, and Possessions)
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a
recall of this type must be adequately repaired within a reasonable time after the customer has
tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not adequately repaired
within a reasonable time, the customer may be entitled to an identical or reasonably equivalent
vehicle at no charge or to a refund of the purchase price less a reasonable allowance for
depreciation. To avoid having to provide these burdensome remedies, every effort must be made
to promptly schedule an appointment with each customer and to repair their vehicle as soon as
possible if requested by the customer. In the recall notification letters, customers are told how to
contact the US National Highway Traffic Safety Administration if the recall is not completed within a
reasonable time.
This bulletin is notice to you that the new motor vehicles included in this recall may not comply with
the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal
for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable
Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles
without first performing the recall correction, your facility may be subject to a civil penalty for each
such sale.
Dealer Recall Responsibility - All
Dealers are to service all vehicles subject to this noncompliance special coverage at no charge to
customers, regardless of mileage, age of vehicle, or ownership, from this time forward if the
customer requests the repair.
THIS INFORMATION IS IN ADDITION TO THE CHILD RESTRAINT INFORMATION CONTAINED
IN YOUR OWNER MANUAL
Where to Put the Restraint
According to accident statistics, children and infants are safer when properly restrained in a child
restraint system or infant restraint system secured in a rear seating position.
General Motors recommends that children and child restraints be secured in a rear seat, including:
an infant or a child riding in a rear-facing child restraint; a child riding in a forward-facing child seat;
an older child riding in a booster seat; and children, who are large enough, using safety belts.
Never put a rear-facing child seat in the front. This is because the risk to the rear-facing child is so
great, if the airbag deploys.
Warning
A child in a rear-facing child restraint can be seriously injured or killed if the right front passenger
airbag inflates. This is because the back of the rear-facing child restraint would be very close to the
inflating airbag. A child in a forward-facing child restraint can be seriously injured or killed if the
right front passenger airbag inflates and the passenger seat is in a forward position.
The vehicle may have a passenger sensing system or a manual airbag on-off switch which is
designed to turn off the right front passenger frontal airbag under certain conditions. Even if the
passenger sensing system or manual airbag on-off switch, if equipped, has turned off the right front
passenger frontal airbag, no system is fail-safe. No one can guarantee that an airbag will not
deploy under some unusual circumstance, even though it is turned off.
Secure rear-facing child restraints in a rear seat, even if the airbag is off. If you secure a
forward-facing child restraint in the right front seat, always move the front passenger seat as far
back as it will go. It is better to secure the child restraint in the back of a vehicle equipped with a
rear seat.
See "Passenger Sensing System" or "Airbag On-Off Switch" in the vehicle owner manual for
additional information.
Warning
A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags
if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a
child restraint in a rear seat.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9030
Do not use child restraints in the center front seat position.
General Motors understands that there may be certain circumstances where it is necessary to
transport a child in a forward-facing child restraint in your vehicle. In these cases, we recommend
placing the forward-facing child restraint in the right front passenger seat where a top tether anchor
is already accessible. The vehicle may have a passenger sensing system or a manual airbag on-off
switch which is designed to turn off the right front passenger frontal airbag under certain conditions.
In addition, a forward-facing child restraint installed in the right front passenger seat would not
interact with the driver frontal airbag. Rear-facing child restraints should not be installed in vehicles
without a rear seat, even if the airbag is off. See "Child Restraints" in the vehicle owner manual for
instructions on how to install a child restraint in the right front seat position.
Securing Forward-Facing Child Restraints (Center Front Seat Position)
For vehicles without rear seats, manufacturers are required to provide top tether anchors for all
non-driver seating positions and instructions for using those anchors. Even if a top tether anchor is
available, you should not install a child restraint in the center front seating position.
Warning
A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags
if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a
child restraint in a rear seat.
In addition, some larger child restraints, if installed in the center front seating position, may interfere
with access to the driver and right front passenger safety belt buckles. See "Safety Belts" in the
vehicle owner manual for information, including warnings, about the importance of safety belt use.
If you must transport a forward-facing child restraint in the center front seat position, you must have
a hole in the back panel trim cover to allow access to the top tether anchor for that position. If your
vehicle does not already have a hole, you must have a service procedure performed on your
vehicle prior to securing a forward-facing child restraint in the center front seat position. Your GM
dealer will cut a hole into the back panel trim cover to allow access to the top tether anchor for the
front center seat position. This service procedure will be performed for you at no charge.
The lap belt would be used to secure a child restraint in this position, following the instructions that
came with the child restraint.
1. Adjust the driver seat to the desired driving position. Fold the armrest up, if equipped. Move the
passenger seat so that the seat and seatback are
aligned with the driver seat and seatback positions. See the appropriate section in the vehicle
owner manual for more information on adjusting the seat and seatback.
2. Place the child restraint on the seat. 3. If the child restraint manufacturer recommends using a
top tether anchor, attach the top tether on the child restraint to the top tether anchor on the
vehicle. Route the top tether according to the child restraint instructions and the following
instructions:
1. Route the top tether over the center seatback or folding armrest, if equipped.
2. Attach the top tether to the slots in the back panel as shown. Do not tighten the top tether at this
time.
4. Pick up the latch plate on the center position lap safety belt, and run the lap safety belt through
the restraint. The child restraint instructions will
show you how.
5. Push the latch plate into the buckle until it clicks. Position the release button on the buckle so
that the safety belt can be unbuckled. 6. Tighten the center position lap belt by pulling on the loose
end of the belt. It may be helpful to use your knee to push down on the child restraint as
you tighten the belt.
7. Tighten the top tether. Follow the child restraint manufacturer's instructions. 8. Before placing a
child in the child restraint, make sure it is securely held in place. To check, grasp the child restraint
at the safety belt path and
attempt to move it side to side and back and forth. When the child restraint is properly installed,
there should be no more than 2.5 cm (1 in) of movement.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9031
Disclaimer
Owner Letter
Owner Letter
December 2010
Dear General Motors Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC
Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a
front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard
(FMVSS) 225 and (CMVSS) 210.1. The top tether anchor for the front center seat is not accessible
and the Owner Manual does not include instructions regarding how to use the top tether. As a
result, GM is conducting a recall. We apologize for this inconvenience. However, we are concerned
about your safety and continued satisfaction with our products.
Important
- Your vehicle is involved in Noncompliance Special Coverage 10407.
- This notice contains important information and instructions to the use of child restraints in your
vehicle.
- Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled?
The child restraint top tether anchor for the front center seat position in your vehicle is not
accessible as required by the Standard. FMVSS 225 also requires that the Owner Manual includes
a step-by-step procedure for attaching a child restraint top tether to a vehicle top tether anchor.
The top tether helps to secure a child seat. Even with the top tether, however, both the National
Highway Traffic Safety Administration and GM discourage placement of a child in a front seat. In
the event of a crash, a child in a child restraint in the front center seat position with or without a top
tether anchor restraint can be seriously injured or killed.
What will we do?
FMVSS 225 requires that we provide the enclosed Owner Manual Supplement that describes how
to install a child restraint using a top tether in the front center seat position; however, General
Motors does not recommend that you place a child restraint in the front center seat. A child in a
child restraint in the front center seat position can be seriously injured or killed by the frontal
airbags if they inflate.
If you must transport a child in a forward-facing child restraint in your vehicle, General Motors
recommends placing the forward-facing child restraint in the right front passenger seat where a top
tether anchor is already accessible. The vehicle may have a passenger sensing system or a
manual on-off switch that is designed to turn off the right front passenger frontal airbag under
certain conditions. In addition, a forward-facing child restraint installed in the right front passenger
seat would not interact with the driver's frontal airbag. Rear-facing child restraints should not be
installed in vehicles without a rear seat, even if the passenger airbag is off. Please refer to the
appropriate section in your Owner Manual for more information.
Your GM dealer will cut a hole into the back panel trim cover to allow access to the top tether
anchor for the front center seat position. See the enclosed insert for an illustration. This service
procedure will be performed for you at no charge. Because of service scheduling requirements, it is
likely that your dealer will need your vehicle longer than the actual service correction time of
approximately 20 minutes.
What should you do?
Please place the enclosed Owner Manual Supplement in your Owner Manual in the Seats and
Restraints section for future reference.
Because a child in a child restraint in the front center seat position can be seriously injured or killed
by the frontal airbags if they inflate, GM does not recommend installing child restraints in the front
center seat position.
You should contact your GM dealer to arrange a service appointment to have an access hole cut
into the back panel trim cover as soon as possible. Until this recall can be performed on your
vehicle, a child restraint top tether cannot be attached to the top tether anchor for the front center
seat position. After
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9032
this procedure has been performed by your dealer, the Owner Manual Supplement provides a
step-by-step procedure for attaching a child restraint top tether to the vehicle top tether anchor for
the front center seat position.
Do you have questions?
If you have questions or concerns that your dealer is unable to resolve, please contact the
appropriate Customer Assistance Center at the number listed below. More information about your
vehicle can be found at the Owner Center at www.gmownercenter.com.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10407
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: >
NHTSA10V575000 > Nov > 10 > Recall 10V575000: Child Restraint Non-Compliance
Child Seat Tether Attachment: All Technical Service Bulletins Recall 10V575000: Child Restraint
Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2011
GMC/Canyon 2004-2011
Isuzu/I-280/I-350 2006
Isuzu/I-290/I-370 2007-2008
MANUFACTURER: General Motors Corp.
MFR'S REPORT DATE: November 18, 2010
NHTSA CAMPAIGN ID NUMBER: 10V575000
NHTSA ACTION NUMBER: N/A
COMPONENT: Child Seat
POTENTIAL NUMBER OF UNITS AFFECTED: 192,676
SUMMARY: GM is recalling certain model year 2004-2011, Chevrolet Colorado, GMC Canyon,
model year 2006, Isuzu I-280/I-350, and model year 2007-2008, I-290/I-370, regular cab vehicles
and extended cab vehicles without a rear seat and equipped with a front 60/40 split bench seat.
These vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard No.
225, "Child Restraint Anchorage Systems." The top tether anchor for the front center seat is not
accessible and the owners manual does not include instructions regarding how to use the top
tether.
CONSEQUENCE: Both NHTSA and GM discourage placement of a child in a front seat.
Nevertheless, there are individual circumstances that may require placement of a child in a
restraint in the front center seating position of this vehicle that does not offer a rear seat. Lack of
access to the top tether anchor and a lack of instructions as to how to use it, may result in improper
installation of a child restraint. Improper installation of a child restraint can result in a reduction in
the restraint's performance in the event of a crash and an increased risk of injury or death to the
child seated in the restraint.
REMEDY: Dealers will cut a hole into the back panel trim cover to allow access to the top tether
anchor for the front center seat position and will provide supplemental information as to use in the
owner's manual. The manufacturer has not yet provided an owner notification schedule for this
campaign. Owners may contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at
1-800-255-6727 or visit GM'S website at www.gmownercenter.com.
NOTES: GM safety recall No. 10367. Owners may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Page 9037
Child Seat Tether Attachment: Service and Repair
Child Seat Restraint System Belt Bracket Replacement
Removal Procedure
1. Remove the bolt securing the child seat restraint bracket to the vehicle. 2. Remove the child seat
restraint bracket from the vehicle.
Installation Procedure
1. Position the child seat restraint bracket by hooking the 2 tabs on the rear of the bracket into the
slots in the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt which retains the child seat restraint bracket to the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Page 9038
Tighten the child seat restraint bracket bolt to 52.5 Nm (39 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions
Seat Belt: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions
INFORMATION
Bulletin No.: 05-09-40-002E
Date: October 21, 2010
Subject: Safety Belt Locking Conditions (Normal Operating Characteristic)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER
H2, H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 05-09-40-002D (Section 09 - Restraints).
The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are
several different locking situations for both front and rear safety belts.
Overspool Lock
There is an unintentional locking condition that ALL safety belts from ALL manufacturers may
experience called "overspool lock". If the webbing snaps back to the stowed position rapidly
enough, the retractor will lock with the belt fully stowed. This is more likely to occur when
customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the
retractive speed of the webbing, the higher than normal webbing retraction speed that occurs
engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the
webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the
locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT
replace the retractor for this condition until first attempting to disengage the locking mechanism by
following the recommendation listed below.
Recommendation
Pull hard on the locked webbing and then release. The hard pull extracts a small amount of
webbing from the retractor which, in turn, permits a small amount of retraction to occur when
released. This is all that is needed to disengage the locking mechanism. The safety belt will now
function properly.
Vehicle Sensing
This type of locking occurs in response to the vehicle under the following conditions:
- The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR
rapid deceleration or there is aggressive cornering).
- It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or
side-to-side), such as streets in San Francisco, California.
- It may also occur over rough road conditions where the retractor mechanism is bounced into a
locked condition.
In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked.
When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt
should return to normal function. Please inform customers that may comment that "the belt locks
intermittently" that this is the design intent and the belt is functioning properly.
Web Sensing
This type of locking occurs in response to the extraction of webbing. When the webbing reels out at
an accelerated rate, it goes into lock mode and stays there until tension is again released. To
observe this condition, extract the webbing quickly. Customers may refer to this condition as
"intermittent lock-up" and encounter it when trying to put the belt on too quickly.
Automatic Locking (ALR)
When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down
mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers
may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to
the end of travel while they are putting the belt on. The ALR mode of operation is automatically
cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function).
Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only,
as a unique feature. Corvette customers may find this feature appealing when they plan to operate
the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the
operator is snugly cinched into the seat and kept firmly in place during high G-force driving
maneuvers.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 9043
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab)
Seat Belt: Service and Repair Front Seat Belt Replacement (Crew Cab)
Front Seat Belt Replacement (Crew Cab)
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
2. Open the front seat belt upper guide shoulder bolt trim cover. 3. Remove the front seat belt
upper guide shoulder bolt. 4. Remove the lower center pillar trim panel. Refer to Center Pillar
Lower Trim Panel Replacement (See: Body and Frame/Interior Moulding /
Trim/Trim Panel/Service and Repair).
5. Remove the front seat belt anchor bolt. 6. Disconnect the electrical connector from the
retractor/pretensioner. 7. Remove the bolt that retains the seat belt retractor/pretensioner assembly
to the body. 8. Remove the front seat belt assembly from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9046
1. Position the rear seat belt retractor/pretensioner assembly to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt which retains the seat belt retractor/pretensioner assembly to the body.
Tighten the front seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft).
3. Connect the electrical connector to the retractor/pretensioner. 4. Install the front seat belt upper
guide with the bolt. Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft).
5. Install the front seat belt upper guide shoulder bolt trim cover. 6. Install the lower center pillar
trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Body and Frame/Interior
Moulding /
Trim/Trim Panel/Service and Repair).
7. Install the front seat belt anchor bolt. Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft).
8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9047
Seat Belt: Service and Repair Front Seat Belt Replacement (Regular and Extended Cab)
Front Seat Belt Replacement (Regular and Extended Cab)
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
2. Open the front seat belt upper guide shoulder bolt trim cover (4). 3. Remove the front seat belt
upper guide shoulder bolt (5). 4. Remove the body rear corner trim panel. Refer to Body Side Rear
Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement
(Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body
Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair). On extended cab models, the front seat belt
retractor/pretensioner is located in the rear door, not the rear corner of the cab.
5. Remove the front seat belt anchor bolt (2). 6. Disconnect the electrical connector from the
retractor/pretensioner (1). 7. Remove the bolt (3) that retains the seat belt retractor/pretensioner
assembly to the body. 8. Remove the front seat belt assembly from the vehicle.
Installation Procedure
1. Position the rear seat belt retractor/pretensioner assembly to the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9048
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt (3) which retains the seat belt retractor/pretensioner assembly (1) to the body.
Tighten the seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft).
3. Connect the electrical connector to the retractor/pretensioner. 4. Install the front seat belt upper
guide with the bolt (5). Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft).
5. Install the front seat belt upper guide shoulder bolt trim cover (4). 6. Install the body rear corner
trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and
Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement
(Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body
Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
7. Install the front seat belt anchor bolt. Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft).
8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9049
Seat Belt: Service and Repair Front Seat Center Belt Replacement
Front Seat Center Belt Replacement
Removal Procedure
1. Remove the rear inboard seat bolt (1) from the passenger seat. 2. Remove the grommet
securing the center seat belt assembly (2) to the seat adjuster. 3. Remove the center seat belt
assembly.
Installation Procedure
1. Position the center seat belt assembly (2) over the rear inboard seat adjuster mounting hole.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9050
2. Install the front seat mounting bolt (1).
Tighten the front seat mounting bolt to 52.5 Nm (39 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9051
Seat Belt: Service and Repair Rear Seat Belt Replacement
Rear Seat Belt Replacement
Removal Procedure
1. Open the rear seat belt upper guide shoulder bolt trim cover. 2. Remove the rear seat belt upper
guide shoulder bolt. 3. Remove the body rear corner trim panel. Refer to Body Side Rear Lower
Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement
(Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body
Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
4. Remove the rear seat belt anchor bolt. 5. Remove the bolt that retains the seat belt retractor
assembly to the body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9052
6. Remove the rear seat belt assembly from the vehicle.
Installation Procedure
1. Position the rear seat belt retractor assembly to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt which retains the seat belt retractor assembly to the body.
Tighten the rear seat belt retractor bolt to 52.5 Nm (39 lb ft).
3. Install the rear seat belt upper guide with the bolt. Ensure that the seat belt webbing is not
twisted.
Tighten the rear seat belt upper guide bolt to 52.5 Nm (39 lb ft).
4. Install the rear seat belt upper guide shoulder bolt trim cover. 5. Install the body rear corner trim
panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and
Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement
(Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body
Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9053
6. Install the rear seat belt anchor bolt. Ensure that the seat belt webbing is not twisted.
Tighten the rear seat belt anchor bolt to 52.5 Nm (39 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9054
Seat Belt: Service and Repair
Front Seat Belt Replacement (Crew Cab)
Front Seat Belt Replacement (Crew Cab)
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
2. Open the front seat belt upper guide shoulder bolt trim cover. 3. Remove the front seat belt
upper guide shoulder bolt. 4. Remove the lower center pillar trim panel. Refer to Center Pillar
Lower Trim Panel Replacement (See: Body and Frame/Interior Moulding /
Trim/Trim Panel/Service and Repair).
5. Remove the front seat belt anchor bolt. 6. Disconnect the electrical connector from the
retractor/pretensioner. 7. Remove the bolt that retains the seat belt retractor/pretensioner assembly
to the body. 8. Remove the front seat belt assembly from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9055
1. Position the rear seat belt retractor/pretensioner assembly to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt which retains the seat belt retractor/pretensioner assembly to the body.
Tighten the front seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft).
3. Connect the electrical connector to the retractor/pretensioner. 4. Install the front seat belt upper
guide with the bolt. Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft).
5. Install the front seat belt upper guide shoulder bolt trim cover. 6. Install the lower center pillar
trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Body and Frame/Interior
Moulding /
Trim/Trim Panel/Service and Repair).
7. Install the front seat belt anchor bolt. Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft).
8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
Front Seat Belt Replacement (Regular and Extended Cab)
Front Seat Belt Replacement (Regular and Extended Cab)
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9056
2. Open the front seat belt upper guide shoulder bolt trim cover (4). 3. Remove the front seat belt
upper guide shoulder bolt (5). 4. Remove the body rear corner trim panel. Refer to Body Side Rear
Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement
(Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body
Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair). On extended cab models, the front seat belt
retractor/pretensioner is located in the rear door, not the rear corner of the cab.
5. Remove the front seat belt anchor bolt (2). 6. Disconnect the electrical connector from the
retractor/pretensioner (1). 7. Remove the bolt (3) that retains the seat belt retractor/pretensioner
assembly to the body. 8. Remove the front seat belt assembly from the vehicle.
Installation Procedure
1. Position the rear seat belt retractor/pretensioner assembly to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9057
2. Install the bolt (3) which retains the seat belt retractor/pretensioner assembly (1) to the body.
Tighten the seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft).
3. Connect the electrical connector to the retractor/pretensioner. 4. Install the front seat belt upper
guide with the bolt (5). Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft).
5. Install the front seat belt upper guide shoulder bolt trim cover (4). 6. Install the body rear corner
trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and
Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement
(Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body
Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
7. Install the front seat belt anchor bolt. Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft).
8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
Front Seat Center Belt Replacement
Front Seat Center Belt Replacement
Removal Procedure
1. Remove the rear inboard seat bolt (1) from the passenger seat. 2. Remove the grommet
securing the center seat belt assembly (2) to the seat adjuster. 3. Remove the center seat belt
assembly.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9058
1. Position the center seat belt assembly (2) over the rear inboard seat adjuster mounting hole.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the front seat mounting bolt (1).
Tighten the front seat mounting bolt to 52.5 Nm (39 lb ft).
Rear Seat Belt Replacement
Rear Seat Belt Replacement
Removal Procedure
1. Open the rear seat belt upper guide shoulder bolt trim cover. 2. Remove the rear seat belt upper
guide shoulder bolt.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9059
3. Remove the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel
Replacement (Regular Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement
(Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body
Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
4. Remove the rear seat belt anchor bolt. 5. Remove the bolt that retains the seat belt retractor
assembly to the body. 6. Remove the rear seat belt assembly from the vehicle.
Installation Procedure
1. Position the rear seat belt retractor assembly to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt which retains the seat belt retractor assembly to the body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9060
Tighten the rear seat belt retractor bolt to 52.5 Nm (39 lb ft).
3. Install the rear seat belt upper guide with the bolt. Ensure that the seat belt webbing is not
twisted.
Tighten the rear seat belt upper guide bolt to 52.5 Nm (39 lb ft).
4. Install the rear seat belt upper guide shoulder bolt trim cover. 5. Install the body rear corner trim
panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and
Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement
(Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body
Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
6. Install the rear seat belt anchor bolt. Ensure that the seat belt webbing is not twisted.
Tighten the rear seat belt anchor bolt to 52.5 Nm (39 lb ft).
Seat Belt Latch Stop Installation
Seat Belt Latch Stop Installation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9061
Seat Belt Replacement - Center Rear (Crew Cab)
Seat Belt Replacement - Center Rear (Crew Cab)
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9062
1. Remove the rear seat shoulder belt guide cover. 2. Remove the body rear trim panel. Refer to
Body Rear Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding /
Trim/Trim
Panel/Service and Repair)Body Rear Trim Panel Replacement (Regular Cab) (See: Body and
Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Rear Trim Panel Replacement
(Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair).
3. Remove the bolt that retains the rear center seat belt assembly to the floor panel. 4. Remove the
rear center seat belt assembly from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Crew Cab) > Page 9063
1. Position the rear center seat belt assembly on the floor panel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt which retains the rear center seat belt assembly to the floor.
Tighten the rear center seat belt bolt to 52.5 Nm (39 lb ft).
3. Route the rear center seat belt webbing up through the guide loop. Ensure that the seat belt
webbing is not twisted. 4. Install the body rear trim panel. Refer to Body Rear Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim
Panel/Service and Repair)Body Rear Trim Panel Replacement (Regular Cab) (See: Body and
Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Rear Trim Panel Replacement
(Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair).
5. Install the rear seat shoulder belt guide cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp
On/Buckling Issues
Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues
INFORMATION
Bulletin No.: 09-09-40-001A
Date: February 02, 2011
Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated
Models:
2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7 X
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-09-40-001 (Section 09 - Restraints).
This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat
belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle
release button sticking.
Analysis of warranty data has determined that this condition may be caused by sticky beverages
being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers,
paper and coins can also contribute to this condition.
Important If foreign material (debris) or sticky liquids are the cause of the concern, show the
customer the condition of the component (buckle assembly) and explain how it is affecting the
function of the restraint system. Strongly recommend that the component be replaced. Point out the
fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the
customer declines to have parts replaced, the service department management must make a
notation on the service record that the lack of functionality of seating position with an inoperative
buckle was fully explained to the customer. The service department management must advise the
customer that having a non-functioning buckle in a seating position voids ability to use that seating
position (no one should ride in the seat). Also make the customer aware that it may be against the
law to ride in a vehicle without wearing a restraint system.
Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do
not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a
spilled liquid as this may damage the buckle.
Use the following steps to determine the cause of the concern.
1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any
debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to
vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If
the system functions properly, do not replace the seat belt buckle assembly.
3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If
sticky residue is found, inform the customer that a
substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle
assembly will need to be replaced at the customer's expense.
4. Refer to SI for seat belt component replacement.
Important If foreign material (debris) or sticky liquids are the cause of the concern, show the
customer the condition of the component (buckle assembly) and explain how it is affecting the
function of the restraint system. Strongly recommend that the component be replaced at the
customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by
the new vehicle warranty. If the customer declines to have parts replaced, the service department
management must make a notation on the service record that the lack of functionality of seating
position with an inoperative buckle was fully explained to the customer. The service department
management must advise customer that having a non-functioning buckle in a seating position voids
ability to use that seating position (no one should ride in the seat). Also make the customer aware
that it may be against the law to ride in a vehicle without wearing a restraint system.
5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional
Checks in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp
On/Buckling Issues > Page 9072
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > Customer Interest: > 07-09-41-010D > May > 10 > Restraints - Airbag Light On DTC B0071
And B0081 Set
Seat Belt Buckle: Customer Interest Restraints - Airbag Light On DTC B0071 And B0081 Set
TECHNICAL
Bulletin No.: 07-09-41-010D
Date: May 03, 2010
Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt
Buckle, If Necessary)
Models:
2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV,
Escalade EXT 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2010
Chevrolet Avalanche, Colorado, Silverado LD, Suburban, Tahoe 2007-2010 GMC Canyon, Sierra
LD, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2006-2010 HUMMER H3 2009-2010
HUMMER H3T
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 07-09-41-010C (Section 09 - Restraints).
Condition
Some customers may comment on the airbag light being illuminated. Upon investigation, the
technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in
the sensing and diagnostics module (SDM).
Correction
Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal,
voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions
for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension
sensor.
Important The seat belt tension sensor is not serviced separately. The seat belt buckle with the
tension sensor must be serviced as a complete unit.
Parts Information
For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714
(trucks) of the appropriate parts catalog.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints
- Seat Belt Warning Lamp On/Buckling Issues
Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling
Issues
INFORMATION
Bulletin No.: 09-09-40-001A
Date: February 02, 2011
Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated
Models:
2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7 X
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-09-40-001 (Section 09 - Restraints).
This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat
belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle
release button sticking.
Analysis of warranty data has determined that this condition may be caused by sticky beverages
being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers,
paper and coins can also contribute to this condition.
Important If foreign material (debris) or sticky liquids are the cause of the concern, show the
customer the condition of the component (buckle assembly) and explain how it is affecting the
function of the restraint system. Strongly recommend that the component be replaced. Point out the
fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the
customer declines to have parts replaced, the service department management must make a
notation on the service record that the lack of functionality of seating position with an inoperative
buckle was fully explained to the customer. The service department management must advise the
customer that having a non-functioning buckle in a seating position voids ability to use that seating
position (no one should ride in the seat). Also make the customer aware that it may be against the
law to ride in a vehicle without wearing a restraint system.
Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do
not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a
spilled liquid as this may damage the buckle.
Use the following steps to determine the cause of the concern.
1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any
debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to
vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If
the system functions properly, do not replace the seat belt buckle assembly.
3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If
sticky residue is found, inform the customer that a
substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle
assembly will need to be replaced at the customer's expense.
4. Refer to SI for seat belt component replacement.
Important If foreign material (debris) or sticky liquids are the cause of the concern, show the
customer the condition of the component (buckle assembly) and explain how it is affecting the
function of the restraint system. Strongly recommend that the component be replaced at the
customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by
the new vehicle warranty. If the customer declines to have parts replaced, the service department
management must make a notation on the service record that the lack of functionality of seating
position with an inoperative buckle was fully explained to the customer. The service department
management must advise customer that having a non-functioning buckle in a seating position voids
ability to use that seating position (no one should ride in the seat). Also make the customer aware
that it may be against the law to ride in a vehicle without wearing a restraint system.
5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional
Checks in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints
- Seat Belt Warning Lamp On/Buckling Issues > Page 9082
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 07-09-41-010D > May > 10 > Restraints
- Airbag Light On DTC B0071 And B0081 Set
Seat Belt Buckle: All Technical Service Bulletins Restraints - Airbag Light On DTC B0071 And
B0081 Set
TECHNICAL
Bulletin No.: 07-09-41-010D
Date: May 03, 2010
Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt
Buckle, If Necessary)
Models:
2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV,
Escalade EXT 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2010
Chevrolet Avalanche, Colorado, Silverado LD, Suburban, Tahoe 2007-2010 GMC Canyon, Sierra
LD, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2006-2010 HUMMER H3 2009-2010
HUMMER H3T
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 07-09-41-010C (Section 09 - Restraints).
Condition
Some customers may comment on the airbag light being illuminated. Upon investigation, the
technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in
the sensing and diagnostics module (SDM).
Correction
Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal,
voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions
for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension
sensor.
Important The seat belt tension sensor is not serviced separately. The seat belt buckle with the
tension sensor must be serviced as a complete unit.
Parts Information
For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714
(trucks) of the appropriate parts catalog.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 07-09-40-002A > Jun > 09 > Restraints Seat Belt Latch Stop Button Availability
Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button
Availability
INFORMATION
Bulletin No.: 07-09-40-002A
Date: June 04, 2009
Subject: Seat Belt Latch Stop Button Available for Service
Models:
2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2
2006-2010 HUMMER H3 2009-2010 HUMMER H3T
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002
(Section 09 - Restraints).
..............................................................................................................................................................
..................................................................................
All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the
button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat
belt retractor assembly does not need replacement.
Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation
procedure.
Parts Information
For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or
Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the
appropriate model year Parts & Illustration Catalog for the vehicle.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 07-09-40-002A > Jun > 09 > Restraints Seat Belt Latch Stop Button Availability
Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button
Availability
INFORMATION
Bulletin No.: 07-09-40-002A
Date: June 04, 2009
Subject: Seat Belt Latch Stop Button Available for Service
Models:
2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2
2006-2010 HUMMER H3 2009-2010 HUMMER H3T
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002
(Section 09 - Restraints).
..............................................................................................................................................................
..................................................................................
All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the
button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat
belt retractor assembly does not need replacement.
Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation
procedure.
Parts Information
For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or
Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the
appropriate model year Parts & Illustration Catalog for the vehicle.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > Page 9096
Seat Belt Buckle: Diagrams
Component Connector End Views
Seat Belt Buckle - Driver
Seat Belt Buckle - Passenger X1
Seat Belt Buckle - Passenger X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > Page 9097
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab)
Seat Belt Buckle: Service and Repair Rear Seat Belt Buckle Replacement (Crew Cab)
Rear Seat Belt Buckle Replacement (Crew Cab)
Removal Procedure
1. Remove the rear bench seat from the vehicle. Refer to Rear Bench Seat Replacement (See:
Body and Frame/Seats/Service and Repair/Rear
Bench Seat Replacement).
2. Remove the grommet securing the rear seat belt buckle assembly to the seat. 3. Remove the
rear seat belt buckle assembly from the seat cushion.
Installation Procedure
1. Install the rear bench seat in the vehicle. Refer to Rear Bench Seat Replacement (See: Body
and Frame/Seats/Service and Repair/Rear Bench
Seat Replacement). Do not install the rear bench seat mounting nut.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab) > Page 9100
2. Install the rear seat belt buckle through the seat cushion loop and position the seat belt buckle
assembly over the rear bench seat mounting hole.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the rear bench seat mounting nut.
Tighten the rear bench seat mounting nut to 52.5 Nm (39 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab) > Page 9101
Seat Belt Buckle: Service and Repair Rear Seat Belt Buckle Replacement (Extended Cab)
Rear Seat Belt Buckle Replacement (Extended Cab)
Removal Procedure
1. Remove the rear folding seat from the vehicle. Refer to Folding Seat Replacement (Extended
Cab) (See: Body and Frame/Seats/Service and
Repair/Folding Seat Replacement (Extended Cab)).
2. Remove the rear seat belt buckle assembly (1) from the vehicle.
Installation Procedure
1. Position the rear seat belt buckle assembly (1) in the vehicle under the inboard leg (2) of the rear
folding seat. 2. Install the rear folding seat in the vehicle. Refer to Folding Seat Replacement
(Extended Cab) (See: Body and Frame/Seats/Service and
Repair/Folding Seat Replacement (Extended Cab)).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab) > Page 9102
Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Center Front
Seat Belt Buckle Replacement - Center Front
Removal Procedure
1. Remove the rear inboard seat bolt from the driver seat. 2. Remove the grommet securing the
center seat belt buckle assembly (1) to the seat adjuster. 3. Remove the center seat belt buckle
assembly (1).
Installation Procedure
1. Position the seat belt buckle assembly (1) over the rear inboard seat adjuster mounting hole.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab) > Page 9103
2. Install the front seat mounting bolt (2).
Tighten the front seat mounting bolt to 52.5 Nm (39 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab) > Page 9104
Seat Belt Buckle: Service and Repair Driver or Passenger Seat Belt Buckle Replacement
Driver or Passenger Seat Belt Buckle Replacement
Removal Procedure
1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Body and
Frame/Seats/Service and Repair/Front Seat
Replacement - Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and
Repair/Split Bench Seat Replacement).
2. Disconnect the seat belt buckle electrical connector (1).
3. Remove the bolt (2) securing the seat belt buckle assembly (1) to the seat adjuster. 4. Pull the
seat belt buckle assembly (1) out though the opening in the seat cushion.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab) > Page 9105
1. Install the seat belt buckle assembly (1) through the seat cushion pad.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the seat belt buckle assembly (1) to the seat adjuster with the bolt (2).
Tighten the front seat belt buckle bolt to 55 Nm (41 lb ft).
3. Connect the seat belt buckle electrical connector (1). 4. Install the seat from the vehicle. Refer to
Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat
Replacement - Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and
Repair/Split Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information >
Technical Service Bulletins > Restraints - Extender Availability For Seat Belt
Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt
INFORMATION
Bulletin No.: 99-09-40-005F
Date: June 23, 2010
Subject: Seat Belt Extender Availability
Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior
HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X
Supercede:
This bulletin is being revised to add the 2009‐2011 model years and update the Warranty
Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints).
Important:
DO NOT use belt extenders when securing a child restraint.
The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient
belt length to accommodate most drivers and passengers. Consequently, requests for belt
extensions (extenders) should be minimal.
Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks
produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15
in). They are designed to be coupled with the existing belts in each vehicle. When in use, the
extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle
will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is
extremely important that the correct length extender be used for the vehicle and occupant intended.
Important:
Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when
you cannot buckle the safety belt without using an extender.
Parts Information
For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or
Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the
appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact
the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada.
Warranty Information
^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their
specific vehicles.
^ Dealers should not be charging part costs since these extenders are supplied by GM to the
dealers.
^ Dealers should not be charging labor costs since the extender can be customer installed.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information
> Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab)
Seat Belt Guide Track: Service and Repair Driver or Passenger Seat Shoulder Belt Guide Adjuster
Replacement (Crew Cab)
Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab)
Removal Procedure
1. Open the front seat belt upper guide shoulder bolt trim cover. 2. Remove the front seat belt
upper guide shoulder bolt. 3. Remove the knob (2) from the front seat belt shoulder adjuster (3). 4.
Remove the upper center pillar trim panel (1). Refer to Center Pillar Upper Trim Panel
Replacement (See: Body and Frame/Interior Moulding /
Trim/Trim Panel/Service and Repair).
5. Remove the 2 bolts securing the adjuster to the vehicle. 6. Remove the front seat belt shoulder
adjuster from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information
> Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9114
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the 2 bolts securing the front seat belt shoulder adjuster (3) to the vehicle.
Tighten the front seat belt shoulder adjuster bolts to 52.5 Nm (39 lb ft).
2. Install the upper center pillar trim panel (1). Refer to Center Pillar Upper Trim Panel
Replacement (See: Body and Frame/Interior Moulding /
Trim/Trim Panel/Service and Repair).
3. Install the knob (2) on the front seat belt shoulder adjuster (3). 4. Install the front seat belt upper
guide with the bolt. Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft).
5. Install the front seat belt upper guide shoulder bolt trim cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information
> Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9115
Seat Belt Guide Track: Service and Repair Driver or Passenger Seat Shoulder Belt Guide Adjuster
Replacement (Extended Cab)
Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Extended Cab)
Removal Procedure
1. Remove the knob (2) from the front seat belt shoulder adjuster (1).
2. Open the front seat belt upper guide shoulder bolt trim cover. 3. Remove the front seat belt
upper guide shoulder bolt. 4. Remove the rear side access door upper trim panel (3). 5. Remove
the 2 bolts securing the adjuster to the vehicle. 6. Remove the front seat belt shoulder adjuster
from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information
> Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9116
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the 2 bolts securing the front seat belt shoulder adjuster (1) to the vehicle.
Tighten the front seat belt shoulder adjuster bolts to 52.5 Nm (39 lb ft).
2. Install the rear side access door upper trim panel (3). 3. Install the front seat belt upper guide
with the bolt. Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft).
4. Install the front seat belt upper guide shoulder bolt trim cover. 5. Install the knob (2) on the front
seat belt shoulder adjuster (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information
> Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9117
Seat Belt Guide Track: Service and Repair Driver or Passenger Seat Shoulder Belt Guide Adjuster
Replacement (Regular Cab)
Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Regular Cab)
Removal Procedure
1. Open the front seat belt upper guide shoulder bolt trim cover. 2. Remove the front seat belt
upper guide shoulder bolt. 3. Remove the knob (2) from the front seat belt shoulder adjuster (1). 4.
Remove the body rear corner upper trim panel (3). Refer to Body Side Upper Trim Panel
Replacement (Regular Cab, Extended Cab) (See: Body
and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Upper Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and
Repair).
5. Remove the 2 bolts securing the adjuster to the vehicle. 6. Remove the front seat belt shoulder
adjuster from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information
> Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9118
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the 2 bolts securing the front seat belt shoulder adjuster (1) to the vehicle.
Tighten the front seat belt shoulder adjuster bolts to 52.5 Nm (39 lb ft).
2. Install the body rear corner upper trim panel (3). Refer to Body Side Upper Trim Panel
Replacement (Regular Cab, Extended Cab) (See: Body
and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Upper Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and
Repair).
3. Install the knob (2) on the front seat belt shoulder adjuster (1). 4. Install the front seat belt upper
guide with the bolt. Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft).
5. Install the front seat belt upper guide shoulder bolt trim cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information
> Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9119
Seat Belt Guide Track: Service and Repair Rear Seat Shoulder Belt Guide Adjuster Replacement
Rear Seat Shoulder Belt Guide Adjuster Replacement
Removal Procedure
1. Open the rear seat belt upper guide shoulder bolt trim cover. 2. Remove the rear seat belt upper
guide shoulder bolt. 3. Remove the knob from the rear seat belt shoulder adjuster (1). 4. Remove
the body rear corner upper trim panel (2). Refer to Body Side Upper Trim Panel Replacement
(Regular Cab, Extended Cab) (See: Body
and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Upper Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and
Repair).
5. Remove the 2 bolts securing the adjuster to the vehicle. 6. Remove the rear seat belt shoulder
adjuster from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information
> Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9120
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the 2 bolts securing the rear seat belt shoulder adjuster (1) to the vehicle.
Tighten the rear seat belt shoulder adjuster bolts to 52.5 Nm (39 lb ft).
2. Install the body rear corner upper trim panel (2). Refer to Body Side Upper Trim Panel
Replacement (Regular Cab, Extended Cab) (See: Body
and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Upper Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and
Repair).
3. Install the knob on the rear seat belt shoulder adjuster (1). 4. Install the rear seat belt upper
guide with the bolt. Ensure that the seat belt webbing is not twisted.
Tighten the rear seat belt upper guide bolt to 52.5 Nm (39 lb ft).
5. Install the rear seat belt upper guide shoulder bolt trim cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions
Seat Belt Retractor: Technical Service Bulletins Restraint System - Normal Safety Belt Locking
Conditions
INFORMATION
Bulletin No.: 05-09-40-002E
Date: October 21, 2010
Subject: Safety Belt Locking Conditions (Normal Operating Characteristic)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER
H2, H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 05-09-40-002D (Section 09 - Restraints).
The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are
several different locking situations for both front and rear safety belts.
Overspool Lock
There is an unintentional locking condition that ALL safety belts from ALL manufacturers may
experience called "overspool lock". If the webbing snaps back to the stowed position rapidly
enough, the retractor will lock with the belt fully stowed. This is more likely to occur when
customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the
retractive speed of the webbing, the higher than normal webbing retraction speed that occurs
engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the
webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the
locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT
replace the retractor for this condition until first attempting to disengage the locking mechanism by
following the recommendation listed below.
Recommendation
Pull hard on the locked webbing and then release. The hard pull extracts a small amount of
webbing from the retractor which, in turn, permits a small amount of retraction to occur when
released. This is all that is needed to disengage the locking mechanism. The safety belt will now
function properly.
Vehicle Sensing
This type of locking occurs in response to the vehicle under the following conditions:
- The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR
rapid deceleration or there is aggressive cornering).
- It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or
side-to-side), such as streets in San Francisco, California.
- It may also occur over rough road conditions where the retractor mechanism is bounced into a
locked condition.
In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked.
When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt
should return to normal function. Please inform customers that may comment that "the belt locks
intermittently" that this is the design intent and the belt is functioning properly.
Web Sensing
This type of locking occurs in response to the extraction of webbing. When the webbing reels out at
an accelerated rate, it goes into lock mode and stays there until tension is again released. To
observe this condition, extract the webbing quickly. Customers may refer to this condition as
"intermittent lock-up" and encounter it when trying to put the belt on too quickly.
Automatic Locking (ALR)
When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down
mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers
may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to
the end of travel while they are putting the belt on. The ALR mode of operation is automatically
cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function).
Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only,
as a unique feature. Corvette customers may find this feature appealing when they plan to operate
the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the
operator is snugly cinched into the seat and kept firmly in place during high G-force driving
maneuvers.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 9125
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 9126
Seat Belt Retractor: Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability
INFORMATION
Bulletin No.: 07-09-40-002A
Date: June 04, 2009
Subject: Seat Belt Latch Stop Button Available for Service
Models:
2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2
2006-2010 HUMMER H3 2009-2010 HUMMER H3T
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002
(Section 09 - Restraints).
..............................................................................................................................................................
..................................................................................
All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the
button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat
belt retractor assembly does not need replacement.
Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation
procedure.
Parts Information
For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or
Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the
appropriate model year Parts & Illustration Catalog for the vehicle.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tension Sensor > Component
Information > Locations
Seat Belt Tension Sensor: Locations
Passenger Compartment/Roof Component Views
Passenger Seat Components - 1 of 2
1 - Inflatable Restraint Seat Belt Tension Sensor - Passenger 2 - Inflatable Restraint Seat Position
Sensor (SPS) - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams
Seat Belt Tensioner: Diagrams
Component Connector End Views
Seat Belt Pretensioner - Driver
Seat Belt Pretensioner - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Page 9133
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures
Seat Belt Tensioner: Procedures
Pretensioner Handling and Scrapping
Warning
When carrying an undeployed inflatable restraint seat belt retractor pretensioner:
* Do not carry the seat belt pretensioner by the seat belt webbing or pigtail connector, if equipped.
* Carry the seat belt pretensioner by the housing, keeping hands and fingers away from the seat
belt webbing.
* Make sure the opening, from which the seat belt webbing extends, faces downward and the seat
belt webbing hangs freely.
Failure to observe these guidelines may result in personal injury.
Scrapping Procedure
During the course of a vehicles useful life, certain situations may arise which will require the
disposal of a live and undeployed seat belt retractor pretensioner. Do not dispose of a live and
undeployed seat belt pretensioner through normal disposal channels until the seat belt
pretensioner has been deployed. The following information covers the proper procedures for
disposing of a live and undeployed seat belt pretensioner. Do not deploy the seat belt retractor
pretensioner in the following situations:
* After replacement of a seat belt retractor pretensioner under warranty. The seat belt retractor
pretensioner may need to be returned undeployed to the manufacturer.
* If the vehicle is the subject of a Product Liability report, GM1241, related to the SIR system or the
seat belt system. If the vehicle is subject to the Product Liability report, do not alter the SIR or seat
belt system in any manner.
* If the vehicle is involved in a campaign affecting the seat belt retractor pretensioners. Follow the
instructions in the Campaign Service Bulletin for proper SIR handling procedures.
Deployment Procedures
The seat belt pretensioner can be deployed inside or outside of the vehicle. The method used
depends upon the final disposition of the vehicle. Review the following procedures in order to
determine which will work best in a given situation.
Deployment Inside the Vehicle
Refer to Inflator Module Handling and Scrapping (See: Air Bag Systems/Air Bag/Service and
Repair) for deploying the pretensioner inside vehicle under Vehicle Scrapping Procedure.
Deployment Outside Vehicle for Seat Belt Pretensioners
Deploy the seat belt pretensioners outside of the vehicle when the vehicle will be returned to
service. Situations that require deployment outside of the vehicle include the following:
* Using the SIR diagnostics, it is determined that the seat belt pretensioner is malfunctioning.
* The seat belt pretensioner pigtail, if equipped, is damaged.
* The seat belt retractor pretensioner connector is damaged.
* The seat belt retractor pretensioner connector terminals are damaged.
Deployment and disposal of a malfunctioning seat belt pretensioner is subject to any required
retention period.
Warning
In order to prevent accidental deployment and the risk of personal injury, do not dispose of an
undeployed inflatable restraint seat belt pretensioner as normal shop waste. Undeployed seat belt
pretensioners contain substances that could cause severe illness or personal injury if their sealed
containers are damaged during disposal. Use the following deployment procedures to safely
dispose of an undeployed seat belt pretensioner. Failure to observe the following disposal methods
may be a violation of federal, state, or local laws.
Special Tools
* J 38826 SIR Deployment Harness
* J 38826-25 for seat belt pretensioner module adapter
* J 39401-B SIR Deployment Fixture
* An appropriate pigtail adaptor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 9136
1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the seat
belt retractor pretensioner from the vehicle. Refer to Seat Belt Retractor Pretensioner Replacement
- Front (Crew Cab) (See:
Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab))Seat
Belt Retractor Pretensioner Replacement - Front (Extended Cab) (See: Removal and
Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt
Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat
Belt Retractor Pretensioner Replacement - Front (Regular Cab)).
5. When carrying a seat belt retractor pretensioner to the deployment area, keep fingers clear of
the seat belt webbing.
6. Clear a space on the ground about 1.85 m (6 ft) in diameter (a) for deployment of the seat belt
pretensioner. If possible, use a paved, outdoor
location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you
have sufficient ventilation.
7. Make sure no loose or flammable objects are in the area. 8. Place the J 39401-B in the center of
the cleared area. 9. Fill the fixture plastic reservoir with water or sand.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Service and Repair > Procedures > Page 9137
10. Mount the seat belt pretensioner (1) in the SIR deployment fixture (3) with the open end facing
up using the following mounting method.
* Adjust and secure the J 39401-B arms (4) to the deployment fixture, with the short slotted
portions of the arms standing vertically and facing toward the center of the deployment fixture.
* To mount, use the proper size bolt (2) and nut (5) with washers in order to secure the seat belt
pretensioner (1) to the deployment fixture brackets.
* Securely tighten all fasteners prior to deployment.
11. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed. 12.
Short the 2 SIR deployment harness (1) leads together using 1 banana plug seated into the other.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 9138
13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 14. Extend the
SIR deployment harness and adapter to full length from the deployment fixture. 15. Connect the
seat belt pretensioner connector to the adapter on the deployment harness.
Note: When deploying a seat belt retractor pretensioner, the rapid expansion of gas is very loud.
Notify the people in the immediate area that a seat belt pretensioner will be deployed.
16. Clear the area of people.
17. Separate the 2 banana plugs on the SIR deployment harness.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 9139
Note: When the seat belt retractor pretensioner deploys, the deployment fixture may jump about 30
cm (1 ft) vertically. This is a normal reaction of the seat belt pretensioner due to the force of the
rapid expansion of gas inside the pretensioner.
18. Place a 12 V minimum/2 A minimum power source, such as a vehicle battery, near the shorted
end of the harness. 19. Connect the SIR deployment harness wires to the power source. Seat belt
pretensioner deployment will occur when contact is made. 20. Disconnect the SIR deployment
harness from the power source after the seat belt retractor pretensioner deploys.
21. Seat one banana plug into the other in order to short the deployment harness leads. 22. If the
seat belt retractor pretensioner did not deploy, disconnect the adapter and discontinue the
procedure. Contact the Technical Assistance
Group. Otherwise, proceed to the following steps.
23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the seat belt retractor
pretensioner as soon as possible. 25. Dispose of the deployed seat belt retractor pretensioner
through normal refuse channels. 26. Wash hands with a mild soap.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 9140
Seat Belt Tensioner: Removal and Replacement
Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab)
Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab)
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
2. Open the front seat belt upper guide shoulder bolt trim cover. 3. Remove the front seat belt
upper guide shoulder bolt. 4. Remove the body rear corner trim panel. Refer to Body Side Rear
Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement
(Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body
Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 9141
5. Remove the front seat belt anchor bolt. 6. Disconnect the electrical connector from the
retractor/pretensioner. 7. Remove the bolt that retains the seat belt retractor/pretensioner assembly
to the body. 8. Remove the front seat belt assembly from the vehicle.
Installation Procedure
1. Position the rear seat belt retractor/pretensioner assembly to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt which retains the seat belt retractor/pretensioner assembly to the body.
Tighten the seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft).
3. Connect the electrical connector to the retractor/pretensioner. 4. Install the front seat belt upper
guide with the bolt. Ensure that the seat belt webbing is not twisted.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 9142
Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft).
5. Install the front seat belt upper guide shoulder bolt trim cover. 6. Install the body rear corner trim
panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and
Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement
(Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body
Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
7. Install the front seat belt anchor bolt. Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft).
8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab)
Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab)
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 9143
2. Open the belt upper guide shoulder bolt trim cover. 3. Remove the front seat belt upper guide
shoulder bolt. 4. Remove the body rear corner trim panel. Refer to Body Side Rear Lower Trim
Panel Replacement (Regular Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement
(Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body
Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
5. Remove the seat belt anchor bolt. 6. Disconnect the electrical connector from the
retractor/pretensioner. 7. Remove the bolt that retains the seat belt retractor/pretensioner assembly
to the body. 8. Remove the seat belt assembly from the vehicle.
Installation Procedure
1. Position the seat belt retractor/pretensioner assembly to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 9144
2. Install the bolt which retains the seat belt retractor/pretensioner assembly to the body.
Tighten the seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft).
3. Connect the electrical connector to the retractor/pretensioner. 4. Install the seat belt upper guide
with the bolt. Ensure that the seat belt webbing is not twisted.
Tighten the seat belt upper guide bolt to 52.5 Nm (39 lb ft).
5. Install the seat belt upper guide shoulder bolt trim cover. 6. Install the seat belt anchor bolt.
Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft).
7. Install the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement
(Regular Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement
(Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body
Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab)
Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab)
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and
Disarming/Service and Repair).
2. Open the front seat belt upper guide shoulder bolt trim cover. 3. Remove the front seat belt
upper guide shoulder bolt. 4. Remove the lower center pillar trim panel. Refer to Center Pillar
Upper Trim Panel Replacement (See: Body and Frame/Interior Moulding /
Trim/Trim Panel/Service and Repair).
5. Remove the front seat belt anchor bolt. 6. Disconnect the electrical connector from the
retractor/pretensioner. 7. Remove the bolt that retains the seat belt retractor/pretensioner assembly
to the body. 8. Remove the front seat belt assembly from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 9145
1. Position the rear seat belt retractor/pretensioner assembly to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt which retains the seat belt retractor/pretensioner assembly to the body.
Tighten the seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft).
3. Connect the electrical connector to the retractor/pretensioner. 4. Install the lower center pillar
trim panel. Refer to Center Pillar Upper Trim Panel Replacement (See: Body and Frame/Interior
Moulding /
Trim/Trim Panel/Service and Repair).
5. Install the front seat belt anchor bolt. Ensure that the seat belt webbing is not twisted.
Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft).
6. Install the front seat belt upper guide with the bolt. Ensure that the seat belt webbing is not
twisted.
Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft).
7. Install the front seat belt upper guide shoulder bolt trim cover. 8. Enable the SIR system. Refer to
SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Door Component Views
Impact Sensor: Locations Door Component Views
Door Component Views
Driver Door Components
1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker
- Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch
(DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF)
Front Passenger Door Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Door Component Views > Page 9151
1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door
Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Door Component Views > Page 9152
Impact Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Front of the Engine Compartment Components
1 - Ambient Air Temperature (AAT) Sensor (DF8) 2 - Horn Assembly 3 - Inflatable Restraint Front
End Sensor - Left 4 - Inflatable Restraint Front End Sensor - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Door Component Views > Page 9153
Impact Sensor: Locations Harness Routing Views
Harness Routing Views
Forward Lamp Harness Routing
1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn
Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right
11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low
Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body
Harness) 16 - X103 (Forward Lamp Harness to Body Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Door Component Views > Page 9154
17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness
(TT5) 19 - Forward Lamp Harness (-TT5)
Driver Door Harness Routing
1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside
Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body
Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver
Front Passenger Door Harness Routing
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Door Component Views > Page 9155
1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front
Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body
Harness) 9 - X210 (Body Harness to Front Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 9156
Impact Sensor: Diagrams
Component Connector End Views
Inflatable Restraint Front End Sensor - Left
Inflatable Restraint Front End Sensor - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 9157
Inflatable Restraint Passenger Presence System (PPS) Sensor
Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 9158
Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement
Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement
Inflatable Restraint Front End Sensor Replacement
Removal Procedure
Warning
Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end
sensor make sure that it is securely fastened. Failure to observe the correct installation procedure
could cause SIR deployment, personal injury, or unnecessary SIR system repairs.
Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s)
Arming and Disarming/Service and Repair). 2. Remove the grille. Refer to Grille Replacement
(See: Body and Frame/Grille/Service and Repair).
3. Loosen the fasteners (1) retaining the front discriminating sensors to the radiator support.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9161
4. Remove the sensor assembly from the radiator support.
5. Position the sensor assembly, to gain access to the electrical connector. 6. Remove the
connector-position assurance (CPA) from the sensor electrical connector. 7. Disconnect the sensor
electrical connector. 8. Remove the sensor from the vehicle.
Installation Procedure
1. Remove any dirt, grease, or other impurities from the mounting surfaces.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9162
2. Position the sensor near the radiator support. 3. Connect the sensor electrical connector. 4.
Install the CPA to the sensor electrical connector.
5. Install the sensor assembly to the radiator support.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9163
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the 2 fasteners (1) retaining the discriminating sensor assembly to the radiator support.
Tighten the bolts to 9 Nm (80 lb in).
7. Install the grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair).
8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s)
Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9164
Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement
Inflatable Restraint Vehicle Rollover Sensor Replacement
Removal Procedure
Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s)
Arming and Disarming/Service and Repair).
2. Fold back the carpet in order to gain access to the sensor. Refer to Floor Panel Carpet
Replacement (See: Body and Frame/Interior Moulding /
Trim/Carpet/Service and Repair).
3. Disconnect the electrical connector. 4. Remove the nuts securing the rollover sensor to the floor
panel.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9165
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the nuts securing the rollover sensor to the floor panel.
Tighten the screws to 10 Nm (88 lb in).
2. Connect the electrical connectors. 3. Install the carpet. Refer to Floor Panel Carpet Replacement
(See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair). 4. Enable the SIR
system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s) Arming and
Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9166
Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement
Inflatable Restraint Side Impact Sensor Replacement
Removal Procedure
Warning
Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the
SIS make sure that it is securely fastened. Failure to observe the correct installation procedures
could cause SIR deployment, personal injury, or unnecessary SIR system repairs.
Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s)
Arming and Disarming/Service and Repair).
2. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair).
3. Peel the rear half of the water deflector away from the door in order to access the side impact
sensor. 4. Remove the screws that retain the side impact sensor to the door. 5. Disconnect the
impact sensor electrical connector from the side impact sensor. 6. Remove the side impact sensor
from the door.
Installation Procedure
1. Remove any dirt, grease, or other impurities from the mounting surface.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9167
2. Position the side impact sensor horizontally to the door. 3. Connect the electrical connector to
the side impact sensor.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the screws which retain the side impact sensor to the door.
Tighten the screws to 9 Nm (79 lb in).
5. Fully seat the water deflector to the door. 6. Install the door trim panel. Refer to Front Side Door
Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Panel/Service and Repair).
7. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s)
Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Tension Sensor
> Component Information > Locations
Seat Belt Tension Sensor: Locations
Passenger Compartment/Roof Component Views
Passenger Seat Components - 1 of 2
1 - Inflatable Restraint Seat Belt Tension Sensor - Passenger 2 - Inflatable Restraint Seat Position
Sensor (SPS) - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information
Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System
Information
INFORMATION
Bulletin No.: 06-08-50-009F
Date: December 23, 2010
Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With
Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices
Models:
2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing
System
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories).
Concerns About Safety and Alterations to the Front Passenger Seat
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT
VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY
ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN
OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF
SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED.
The front passenger seat in many GM vehicles is equipped with a passenger sensing system that
will turn off the right front passenger's frontal airbag under certain conditions, such as when an
infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the
right front passenger's seat mounted side impact airbag. For the system to function properly,
sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger
sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers,
upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by
GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an
aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or
between the occupant and the seat fabric.
Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM
ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR
SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE
APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH
IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE
NECESSARY BY SUCH USE.
Many types of aftermarket accessories are available to customers, upfitting shops, and dealers.
Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat
heaters are installed under the seat fabric. Additionally, seat covers made of leather or other
materials may have different padding thickness installed that could prevent the Passenger Sensing
System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to
the seat cushion, as this may interfere with the operation of the Passenger Sensing System and
either prevent proper deployment of the passenger airbag or prevent proper suppression of the
passenger air bag.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Technical Service Bulletins > Page 9175
Seat Occupant Sensor: Locations
Passenger Compartment/Roof Component Views
Passenger Seat Components - 2 of 2
1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence
System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Technical Service Bulletins > Page 9176
Seat Occupant Sensor: Service and Repair
Inflatable Restraint Passenger Presence System Replacement - Front
Removal Procedure
Warning
Replace the passenger presence system as a complete assembly to prevent possible injury to the
occupant. The bladder, the pressure sensor, the seat cushion, and the control module are
assembled and calibrated as a unit. Using only some of the components in the service kit will
cause the passenger presence system to operate improperly.
1. Remove the seat cushion trim cover and pad. 2. Disconnect the electrical connectors. 3.
Remove the bolts that retain the electronic control unit (ECU) (1) from the bottom of the passenger
seat cushion frame. 4. Remove the pressure switch (2) from the bottom of the passenger seat
cushion frame.
5. Remove the push-in retainers (1) that hold the bladder to the seat cushion frame. 6. Remove the
inflatable restraint passenger presence system from the seat.
Installation Procedures
1. Install the inflatable restraint passenger presence system to the seat. 2. Install the push-in
retainers (1) that hold the bladder to the seat cushion frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Technical Service Bulletins > Page 9177
3. Install the pressure sensor (2) to the bottom of the passenger seat cushion frame.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the bolts that retain the ECU (1) to the bottom the passenger seat cushion frame.
Tighten the bolts to 2 Nm (18 lb in).
5. Connect the electrical connectors. 6. Install the seat cushion trim cover and pad. 7. Re-zero the
inflatable restraint passenger presence system. Refer to Control Module References (See: Testing
and Inspection/Programming and
Relearning).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Component Information > Locations
Seat Position Sensor: Locations
Passenger Compartment/Roof Component Views
Under the Driver Seat Components
1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1)
5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver
Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver
Passenger Seat Components - 1 of 2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Component Information > Locations > Page 9181
1 - Inflatable Restraint Seat Belt Tension Sensor - Passenger 2 - Inflatable Restraint Seat Position
Sensor (SPS) - Passenger
Under the Passenger Seat Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Component Information > Locations > Page 9182
1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor
(SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger
(KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1)
7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Component Information > Locations > Page 9183
Seat Position Sensor: Diagrams
Component Connector End Views
Inflatable Restraint Seat Position Sensor - Left
Inflatable Restraint Seat Position Sensor - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Component Information > Locations > Page 9184
Seat Position Sensor: Service and Repair
Inflatable Restraint Seat Position Sensor Replacement (Power Seat)
Removal Procedure
1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Body and
Frame/Seats/Service and Repair/Front Seat
Replacement - Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and
Repair/Split Bench Seat Replacement).
2. Ensure that the seat is in the full rear position.
3. Locate the seat position sensor (1) under the seat on the inside of the inner seat rail. 4.
Disconnect the electrical connector (3) from the seat position sensor (1). 5. Remove the 2 nuts (2)
that retain the seat position sensor to the seat rail. 6. Remove the seat position sensor from the
seat.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Component Information > Locations > Page 9185
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the seat position sensor (1) to the seat rail with 2 nuts (2).
Tighten the seat position sensor nuts to 9 Nm (79 lb in).
2. Connect the electrical connector (13) to the seat position sensor (1). 3. Install the seat in the
vehicle. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and
Repair/Front Seat Replacement
- Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split
Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Relay > Component Information >
Locations
Accessory Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information
> Technical Service Bulletins > Audio System - Difficult To Install Fixed Radio Antenna
Antenna Mast: Technical Service Bulletins Audio System - Difficult To Install Fixed Radio Antenna
INFORMATION
Bulletin No.: 07-08-44-001F
Date: June 15, 2010
Subject: Information on Difficult to Install Fixed Radio Antenna Mast
Models:
2006-2011 Cadillac Escalade EXT 2005-2010 Chevrolet Cobalt 2006-2009 Chevrolet TrailBlazer
Models 2006-2011 Chevrolet Avalanche, Colorado, Silverado (Classic and New Style) 2006-2009
GMC Envoy 2006-2011 GMC Canyon, Sierra (Classic and New Style) 2006-2010 Pontiac G5
2006-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years, a graphic with accompanying text
and additional text in the Parts Information Description. Please discard Corporate Bulletin Number
07-08-44-001E (Section 08 - Body and Accessories).
- A design change was made to the antenna base and antenna mast starting in October 2005. The
radio antenna base size increased from 6 mm (0.23 in) to 7 mm (0.27 in) for improved stability and
radio reception.
- There are two different design antenna masts available. The antenna masts can be distinguished
by the outer bottom of the antenna mast. The first design antenna mast (1) will have a six-sided
hex design and a 6 mm (0.23 in) inside diameter thread. The second design antenna mast (2) will
have two flats on the outer mast and a 7 mm (0.27 in) inside diameter thread.
- The second design antenna mast will have more resistance when installing due to the
interference fit of the threads in the mast as identified by the arrows in the graphic.
Note Before proceeding, verify that the mast and base stud are properly aligned.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information
> Technical Service Bulletins > Audio System - Difficult To Install Fixed Radio Antenna > Page 9195
- A wrench will be needed to install the antenna mast. When starting to thread the antenna mast
onto the base stud, interference will be felt. The interference is similar to the feeling of a cross
threaded fastener.
Important Use a protective tape or a cloth inside an adjustable wrench when installing the antenna
mast. This will help prevent damage to the painted coating on the antenna mast.
- Tighten the antenna mast.
Tighten Tighten to 6 Nm (53 lb in).
Parts Information
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information
> Technical Service Bulletins > Page 9196
Antenna Mast: Service and Repair
Fixed Antenna Mast Replacement
Removal Procedure
1. Use the tool (1) provided with the vehicle to unscrew the antenna mast.
2. Remove the antenna mast from the antenna base.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information
> Technical Service Bulletins > Page 9197
1. Install the antenna mast to the antenna base.
Important: Install the antenna mast using the mast tool. Ensure the antenna mast is fully seated to
the antenna base.
2. Using the mast tool, tighten the antenna mast (1) until fully seated to the antenna base (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component
Information > Service and Repair
Antenna, Navigation: Service and Repair
Cellular and Navigation Antenna Assembly Replacement
Removal Procedure
1. Lower the front portion of the headliner. Refer to Headlining Trim Panel Replacement (Extended
Cab) (See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
2. Disconnect the electrical connectors from the antenna assembly. 3. Loosen the retaining nut
until the assembly can be removed from the roof panel. 4. Using an upward motion, remove the
antenna assembly from the roof.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component
Information > Service and Repair > Page 9201
1. Install the antenna assembly from the top of the roof. 2. Lower the antenna assembly to the roof
panel, ensuring the anti-rotation pin is properly indexed.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the retaining nut.
Tighten the nut to 6 Nm (53 lb in).
4. Connect the antenna electrical connectors. 5. Install the headliner. Refer to Headlining Trim
Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component
Information > Service and Repair > Cellular Communications/Digital Radio Antenna Replacement
Antenna, Phone: Service and Repair Cellular Communications/Digital Radio Antenna Replacement
Cellular Communications/Digital Radio Antenna Replacement
Removal Procedure
1. Lower the front portion of the headliner. Refer to Headlining Trim Panel Replacement (Extended
Cab) (See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
2. Disconnect the electrical connectors from the digital radio antenna assembly. 3. Remove the
retaining bolt and retainer from the antenna. 4. Squeeze the plastic retainer to release the antenna
assembly from the roof panel. 5. Using an upward motion, remove the antenna assembly from the
roof.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component
Information > Service and Repair > Cellular Communications/Digital Radio Antenna Replacement > Page 9206
1. Install the antenna assembly to the top of the roof. 2. Lower the antenna assembly to the roof
panel, ensuring the anti-rotation pin is properly indexed.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the retainer and retainer bolt.
Tighten the bolt to 6 Nm (53 lb in).
4. Connect the antenna electrical connectors. 5. Install the headliner. Refer to Headlining Trim
Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component
Information > Service and Repair > Cellular Communications/Digital Radio Antenna Replacement > Page 9207
Antenna, Phone: Service and Repair Cellular and Navigation Antenna Assembly Replacement
Cellular and Navigation Antenna Assembly Replacement
Removal Procedure
1. Lower the front portion of the headliner. Refer to Headlining Trim Panel Replacement (Extended
Cab) (See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
2. Disconnect the electrical connectors from the antenna assembly. 3. Loosen the retaining nut
until the assembly can be removed from the roof panel. 4. Using an upward motion, remove the
antenna assembly from the roof.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component
Information > Service and Repair > Cellular Communications/Digital Radio Antenna Replacement > Page 9208
1. Install the antenna assembly from the top of the roof. 2. Lower the antenna assembly to the roof
panel, ensuring the anti-rotation pin is properly indexed.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Tighten the retaining nut.
Tighten the nut to 6 Nm (53 lb in).
4. Connect the antenna electrical connectors. 5. Install the headliner. Refer to Headlining Trim
Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component
Information > Service and Repair > Cellular Communications/Digital Radio Antenna Replacement > Page 9209
Antenna, Phone: Service and Repair Mobile Telephone Digital Antenna Replacement
Mobile Telephone Digital Antenna Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement
Antenna Cable: Service and Repair Radio Antenna Cable Extension Cable Replacement
Radio Antenna Cable Extension Cable Replacement
Removal Procedure
1. Remove the accessory trim panel. Refer to Instrument Panel Accessory Trim Plate Replacement
(See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
2. Remove the radio. Refer to Radio Replacement (See: Radio, Stereo, and Compact
Disc/Radio/Stereo/Service and Repair/Radio Replacement). 3. Lower the instrument panel (I/P)
compartment door to a full down position.
4. Disconnect the radio extension antenna cable (1). 5. Remove the clip retaining the extension
cable. 6. Remove the cable from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9215
1. Install the cable to the vehicle. 2. Install the clip retaining the extension cable. 3. Connect the
radio extension antenna cable (1). 4. Close the I/P compartment door. 5. Install the radio. Refer to
Radio Replacement (See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and
Repair/Radio Replacement). 6. Install the accessory trim panel. Refer to Instrument Panel
Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9216
Antenna Cable: Service and Repair Digital Radio Antenna Cable Replacement
Digital Radio Antenna Cable Replacement
Removal Procedure
1. If the vehicle is equipped with OnStar(R) refer to Mobile Telephone and Navigation Antenna
Coaxial Cable Replacement (UE1) (See: Mobile
Telephone and Navigation Antenna Coaxial Cable Replacement (UE1))Mobile Telephone and
Navigation Antenna Coaxial Cable Replacement (UE1, U2K) (See: Mobile Telephone and
Navigation Antenna Coaxial Cable Replacement (UE1, U2K)).
2. Lower the front portion of the headliner to reveal the digital radio antenna connectors. Refer to
Headlining Trim Panel Replacement (Extended
Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim
Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair).
3. Disconnect the digital radio antenna connectors (1). 4. Detach the 2 upper coax cable retainers
from the header panel. 5. Detach the 3 coax cable retainers from the windshield pillar. 6. Lower the
instrument panel (I/P) compartment door to a full down position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9217
7. Disconnect the digital receiver extension cable (1) from the receiver. 8. Remove the retainers (2)
from the I/P. 9. Disconnect the electrical connector (3).
10. Remove the extension cable from the vehicle.
11. Detach the coax cable retainer (3) from the I/P. 12. Attach a mechanics wire to the end of the
coax cable (2). 13. Detach the coax cable retainer (4) from the hinge pillar. 14. Grasp the cable (1)
and pull upward to release the retainer from the hinge pillar. 15. Pull upward to remove the cable
from behind the I/P. 16. Remove the cable from the vehicle leaving the mechanics wire behind the
I/P.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9218
1. Attach the existing mechanics wire to the end of the coax cable (2). 2. Pull downward on the
mechanics wire to install the cable behind the I/P. 3. Attach the coax cable retainer (4) to the hinge
pillar. 4. Attach the coax cable retainer (3) to the I/P.
5. Connect the digital receiver extension cable (1) to the receiver. 6. Attach the retainers (2) to the
I/P. 7. Connect the electrical connector (3). 8. Close the (I/P) compartment door. 9. Attach the 3
coax cable retainers to the windshield pillar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9219
10. Connect the digital radio antenna connectors (1). 11. Attach the 2 upper coax cable retainers to
the header panel. 12. Install the headliner. Refer to Headlining Trim Panel Replacement (Extended
Cab) (See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9220
Antenna Cable: Service and Repair Antenna Cable Replacement
Antenna Cable Replacement
Removal Procedure
1. Remove the right front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (See:
Body and Frame/Interior Moulding /
Trim/Scuff Plate/Service and Repair).
2. Remove the right hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement Left Side (See: Body and Frame/Interior
Moulding / Trim/Trim Panel/Service and Repair).
3. Remove the instrument panel (I/P) compartment door. Refer to Instrument Panel Compartment
Door Replacement (See: Body and Frame/Interior
Moulding / Trim/Glove Compartment/Service and Repair).
4. Disconnect the radio antenna cable (1) from the extension cable. 5. Remove the grommet from
the hinge pillar in an outbound direction. 6. Attach a mechanics wire to the to the antenna cable (1).
7. Remove the antenna mast. Refer to Fixed Antenna Mast Replacement (See: Antenna
Mast/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9221
8. Remove the screws retaining the antenna base.
9. Remove the grommet (1) and cable from the routing hole.
10. Remove the antenna cable from the vehicle. 11. Leave the mechanics wire in place for
assembly purposes.
Installation Procedure
1. Attach the mechanics wire to the end of the antenna cable.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9222
2. Pull on the mechanics wire to route the cable and grommet (1) through the hinge pillar.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the screws retaining the antenna base.
Tighten the screws to 7.5 Nm (66 lb in).
4. Install the antenna mast. Refer to Fixed Antenna Mast Replacement (See: Antenna Mast/Service
and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9223
5. Remove the mechanics wire from the antenna cable (1). 6. Install the grommet to the hinge
pillar. 7. Connect the radio antenna cable (1) to the extension cable. 8. Install the I/P compartment
door. Refer to Instrument Panel Compartment Door Replacement (See: Body and Frame/Interior
Moulding /
Trim/Glove Compartment/Service and Repair).
9. Install the right hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Left
Side (See: Body and Frame/Interior Moulding
/ Trim/Trim Panel/Service and Repair).
10. Install the right front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (See:
Body and Frame/Interior Moulding / Trim/Scuff
Plate/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9224
Antenna Cable: Service and Repair Mobile Telephone and Navigation Antenna Coaxial Cable
Replacement (UE1)
Mobile Telephone and Navigation Antenna Coaxial Cable Replacement (UE1)
Removal Procedure
1. Lower the front portion of the headliner to reveal the coax cable leading to the navigation and
cellular telephone antenna connectors (1). Refer to
Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
2. Disconnect the coax cable connectors (1). 3. Detach the fasteners retaining the coax cable to
the header panel.
4. Detach the 3 coax cable retainers from the windshield pillar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9225
5. Open the instrument panel (I/P) compartment door to a full down position. 6. Disconnect the
antenna coax cable (2) from the vehicle communication interface module (VCIM) jumper harness.
7. Detach the retainers from the I/P structure. 8. Attach a mechanics wire to the end of the coax
cable (2). 9. Detach the coax cable retainer (4) from the hinge pillar.
10. Grasp the cable (1) and gently pull upward to release the retainer (5) from the hinge pillar. 11.
Continue pulling the cable upward to remove the cable from behind the I/P. 12. Remove the cable
from the vehicle leaving the mechanics wire routed behind the I/P.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9226
1. Attach a mechanics wire to the end of the coax cable (1). 2. Carefully remove the coax cable
retainer (4) from the cable. 3. Grasp the mechanics wire and gently pull downward to route the
cable behind the I/P. 4. Attach the retainer (4) to the hinge pillar. 5. Attach the remaining lower
retainers to the I/P structure.
6. Connect the antenna coax cable (2) to the VCIM jumper harness. 7. Close the I/P compartment
door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9227
8. Attach the 3 coax cable retainers to the windshield pillar.
9. Attach the fasteners retaining the coax cable to the header panel.
10. Connect the coax cable connectors (1). 11. Install the headliner. Refer to Headlining Trim Panel
Replacement (Extended Cab) (See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9228
Antenna Cable: Service and Repair Mobile Telephone and Navigation Antenna Coaxial Cable
Replacement (UE1, U2K)
Mobile Telephone and Navigation Antenna Coaxial Cable Replacement (UE1, U2K)
Removal Procedure
1. Lower the front portion of the headliner to reveal the coax cables and wiring harness assembly.
Refer to Headlining Trim Panel Replacement
(Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding
/ Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair).
2. Disconnect the connectors to the navigation cellular telephone antenna (1). 3. Detach the
fasteners retaining the coax cable to the header panel. 4. Disconnect the connectors to the digital
radio antenna (2).
5. Detach the 3 coax cable retainers from the windshield pillar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9229
6. Open the instrument panel (I/P) compartment door to a full down position. 7. Disconnect the
connector (2) from the vehicle communication interface module (VCIM) jumper harness. 8.
Disconnect the connector (1) from the digital radio receiver jumper harness.
9. Detach the retainer (3) from the I/P structure.
10. Attach a mechanics wire to the end of the coax cable (1) and (2). 11. Detach the coax cable
retainer (4) from the hinge pillar. 12. Grasp the cable above the I/P and gently pull upward to
release the retainer (5) from the hinge pillar. 13. Continue pulling the cable upward to remove the
cable from behind the I/P. 14. Remove the cable from the vehicle leaving the mechanics wire
routed behind the I/P.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9230
1. Attach a mechanics wire to the end of the coax cable (1) and (2). 2. Carefully remove the coax
cable retainer (4) from the cable. 3. Grasp the mechanics wire and gently pull downward to route
the cable behind the I/P. 4. Attach the retainer (4) to the hinge pillar. 5. Attach the remaining lower
retainers to the I/P structure.
6. Install the connectors (2) to the VCIM jumper harness. 7. Install the connectors (1) to the digital
radio receiver jumper harness. 8. Close the I/P compartment door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9231
9. Attach the 3 coax cable retainers to the windshield pillar.
10. Install the connectors to the digital radio antenna (2). 11. Attach the fasteners retaining the
coax cable to the header panel. 12. Install the coax cable connectors (1). 13. Install the headliner.
Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior
Moulding /
Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body
and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel
Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module,
(Vehicle Antitheft) > Component Information > Diagrams
Alarm Module: Diagrams
Component Connector End Views
Theft Deterrent Module (TDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Transmitter > Component Information > Service and Repair
Keyless Entry Transmitter: Service and Repair
Transmitter Programming
Important: Up to 4 transmitters can be programmed. Do not operate or program the transmitters in
the vicinity of other vehicles that are in the keyless entry program mode. This prevents the
programming of the transmitters to the incorrect vehicle. The order in which the transmitters are
programmed is important. The first transmitter programmed will be transmitter #1, and the second
transmitter programmed will be transmitter #2. Use care to program the transmitters correctly.
Important: All key fobs must be programmed each time any one fob is programmed. The scan tool
must stay connected until all of the transmitters are programmed.
1. Install a scan tool and navigate to the BCM Module Setup menu. 2. Select Program Key Fobs. 3.
Follow the scan tool on-screen directions. 4. When the programming operations have completed,
operate the transmitter functions to verify correct system operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Service and Repair
Cellular Phone Microphone: Service and Repair
Mobile Telephone Microphone Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls
to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls
to OnStar(R) > Page 9252
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls
to OnStar(R) > Page 9253
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls
to OnStar(R) > Page 9254
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 08-08-46-008C > Jan > 11 > OnStar(R) Generation 8.0L Software Update
Communications Control Module: Customer Interest OnStar(R) - Generation 8.0L Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 08-08-46-008C > Jan > 11 > OnStar(R) Generation 8.0L Software Update > Page 9260
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Communications Control Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L
Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9266
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9271
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9272
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9273
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 9278
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R)
Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute
Enough When Using OnStar(R)
TECHNICAL
Bulletin No.: 10-08-46-001
Date: January 27, 2010
Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are
Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R)
Customer Service)
Models:
2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009
Saab 9-7X All Equipped with OnStar(R) (RPO UE1)
Condition
Some customers may comment that when the radio is on, it does not mute enough when the
OnStar(R) Turn-by-Turn Navigation directions are announced.
Cause
This condition may be caused by the customer improperly setting the radio volume high enough
when the Turn-by-Turn Navigation messages are played.
The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on
during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can
still be heard at a very low volume. Previous model years initiated a "hard mute" during this
function which completely muted the radio audio.
Correction
Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation
direction announcements. You can control the message volume using the radio volume control,
only when the Turn-by-Turn navigation messages are playing.
Some customers that were accustomed to previous model vehicles with the "hard mute" feature
may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the
OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained
Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the
hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then
create a case number. Advise the customer that the vehicle update should be completed Over the
Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the
customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise
them to press the Blue OnStar(R) Button and ask for Customer Care to check status.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 9283
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Communications Control Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L
Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9289
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 9294
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R)
Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute
Enough When Using OnStar(R)
TECHNICAL
Bulletin No.: 10-08-46-001
Date: January 27, 2010
Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are
Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R)
Customer Service)
Models:
2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009
Saab 9-7X All Equipped with OnStar(R) (RPO UE1)
Condition
Some customers may comment that when the radio is on, it does not mute enough when the
OnStar(R) Turn-by-Turn Navigation directions are announced.
Cause
This condition may be caused by the customer improperly setting the radio volume high enough
when the Turn-by-Turn Navigation messages are played.
The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on
during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can
still be heard at a very low volume. Previous model years initiated a "hard mute" during this
function which completely muted the radio audio.
Correction
Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation
direction announcements. You can control the message volume using the radio volume control,
only when the Turn-by-Turn navigation messages are playing.
Some customers that were accustomed to previous model vehicles with the "hard mute" feature
may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the
OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained
Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the
hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then
create a case number. Advise the customer that the vehicle update should be completed Over the
Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the
customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise
them to press the Blue OnStar(R) Button and ask for Customer Care to check status.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 9299
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9305
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9306
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9307
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 9312
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 9317
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Page 9318
Communications Control Module: Diagrams
Component Connector End Views
Vehicle Communications Interface Module (VCIM) X1
Vehicle Communications Interface Module (VCIM) X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Page 9319
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Page 9320
Communications Control Module: Service and Repair
Communication Interface Module Replacement
Removal Procedure
Note: The vehicle communication interface module (VCIM) has a specific set of unique numbers
that tie the module to each vehicle. These numbers, the 10-digit station identification (STID) and
the 11-digit electronic serial number (ESN), are used by the National Cellular Network and
OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle
identification number of the vehicle, you must never exchange these parts with those of another
vehicle.
1. Ensure the ignition switch is in the OFF position.
2. Remove the service panel located on the right side of the instrument panel (I/P).
3. Disconnect the VCIM electrical connectors as necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Page 9321
4. Remove the screw retaining the VCIM to the bracket.
5. Release the tab (1) on the bracket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Page 9322
6. Remove the VCIM from the bracket.
7. Remove the VCIM from the vehicle.
Installation Procedure
1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the
labels on the new module.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Page 9323
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the VCIM to the bracket ensuring the retaining tab (1) is fully seated.
Tighten the screw fully driven , seated and not stripped.
3. Connect the VCIM electrical connectors as necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Page 9324
4. Install the service panel.
Note: After replacing the VCIM, you must reconfigure the OnStar(R) system. Failure to reconfigure
the system will result in an additional customer visit for repair. In addition, pressing and holding the
white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will
cause a DTC to set.
5. Reconfigure the OnStar(R) system. Refer to Control Module References (See: Testing and
Inspection/Programming and Relearning). 6. When replacing the communication interface module
be sure to transfer Bluetooth Antenna, if equipped.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Central Control Module > Component Information >
Locations > Instrument Panel/Center Console Component Views
Central Control Module: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Below the I/P Components - 1 of 2
1 - Vehicle Communication Interface Module (VCIM) X1 (UE1) 2 - Vehicle Communication Interface
Module (VCIM) X2 (UE1) 3 - Vehicle Communication Interface Module (VCIM) (UE1) 4 - I/P
Courtesy Lamp - Right 5 - I/P Courtesy Lamp - Left 6 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Central Control Module > Component Information >
Locations > Instrument Panel/Center Console Component Views > Page 9329
Central Control Module: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Central Control Module > Component Information >
Locations > Instrument Panel/Center Console Component Views > Page 9330
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Description and Operation
Driver/Vehicle Information Display: Description and Operation
Driver Information Center (DIC) Description and Operation
Driver Information Center (DIC)
The driver information center (DIC) consists of a double line 14 character display placed in the
lower center area of the instrument panel cluster (IPC). The DIC will display vehicle information,
configuration, and warning parameters to the driver.
The display parameters are cycled, changed, and acknowledged using a control stem. Pressing the
stem for 1 second will display the DIC options. Pressing the stem for more than 2 seconds will
select an option.
DIC Displays
The driver information center (DIC) parameters are displayed by order of priority as follows (from
highest to lowest) :
* Service Diagnostics
* Feature Programming
* Driver Warnings
* Vehicle Information
Vehicle Information
Vehicle information provides feedback to the driver on vehicle performance, mileage, maintenance
or related information. When the English/Metric status changes, any applicable vehicle information
data values will also change.
Odometer
The odometer is capable of displaying values from 0-999,999 KM or MI. If the ignition is in the OFF
or UNLOCK/ACC position, the odometer can be displayed by pressing the trip/reset switch. The
odometer will remain displayed for 5 seconds.
Trip Odometers
The trip odometer is capable of displaying values from 0-9999.9 KM or MI. When the maximum
value is reached, the trip odometer will roll over to 0.0. Holding the control stem for greater than 4
seconds while the trip odometer is displayed will reset the displayed trip odometer to 0.0 upon
release of the stem. The trip odometer will remain displayed after being reset.
Engine Oil Life
Engine Oil Life percentage values are based on serial data messages to the instrument panel
cluster (IPC). The IPC requests this value when Engine Oil Life is selected on the DIC. Engine Oil
Life is capable of displaying values from 0 to 100%. Pressing the control stem for longer than 2
seconds while Engine Oil Life is displayed on the DIC will reset the value to 100%. An audible
warning will sound confirming that the system has been reset. Display appears as OIL LIFE:
XXX%.
Display Language
The driver information center (DIC) is capable of displaying messages in more than one language.
The DIC language selection procedure is as follows:
1. With the engine OFF, turn the key to ON, but do not start the engine. 2. Close all doors so the
DOORS message does not display in the DIC. 3. Momentarily press and release the trip reset stem
until the current language is displayed: English, French or Spanish. 4. To select a different
language, press and hold the trip reset stem until the next language appears. 5. Repeat Step 4 until
the desired language is displayed. Once the desired language is shown on the DIC display, the
language is set. 6. To exit language selection, momentarily press and release the trip stem. All DIC
messages will now display in the language selected.
Feature Programming
Refer to Personalization Description and Operation (See: Description and
Operation/Personalization Description and Operation).
Driver Warnings
For the list of Driver Warnings, refer to Indicator/Warning Message Description and Operation
(See: Instrument Panel, Gauges and Warning Indicators/Description and
Operation/Indicator/Warning Message Description and Operation).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number
Incorrect/Incorrectly Assigned
Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number
Incorrect/Incorrectly Assigned > Page 9342
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C
> Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number
Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C
> Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 9348
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D
> May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004
> Aug > 08 > OnStar(R) - Aftermarket Device Interference Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D >
May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 >
Aug > 08 > OnStar(R) - Aftermarket Device Interference Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning
System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System
Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Global Positioning System Module: Customer Interest OnStar(R) - Generation 8.0L Software
Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning
System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System
Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9375
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning
System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global
Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Global Positioning System Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L
Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning
System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global
Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9381
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module >
Component Information > Technical Service Bulletins > Customer Interest: > 08-08-46-008C > Jan > 11 > OnStar(R) Generation 8.0L Software Update
Navigation Module: Customer Interest OnStar(R) - Generation 8.0L Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module >
Component Information > Technical Service Bulletins > Customer Interest: > 08-08-46-008C > Jan > 11 > OnStar(R) Generation 8.0L Software Update > Page 9391
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-46-008C > Jan > 11 >
OnStar(R) - Generation 8.0L Software Update
Navigation Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-46-008C > Jan > 11 >
OnStar(R) - Generation 8.0L Software Update > Page 9397
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-08-50-006 >
Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck
Seat Track: All Technical Service Bulletins Interior - Front Manual Seat(s) Won't Adjust, Stuck
TECHNICAL
Bulletin No.: 10-08-50-006
Date: June 02, 2010
Subject: Front Manual Seat(s) Won't Adjust Forward or Rearward, Sticks or Binds (Install Revised
Seat Adjuster Bar, Replace Seat Adjuster)
Models:
2004-2010 Chevrolet Colorado 2004-2010 GMC Canyon with Seat RPO AM6 or AR9
Condition
Some customers may comment that the front seat(s) appear to be stuck in position and they are
unable to move the seat forward or rearward in the vehicle.
Cause
This condition may be caused by the seat adjuster bar (handle) bending or coming out of position.
This may also cause damage to the plastic adjuster blocks located in the seat adjuster assembly.
Seat tracks (adjuster assemblies) that are not parallel to each other may contribute to the
development of this condition.
Correction
Use the following procedure to repair the affected seat(s).
1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket or Split Bench
Seat Replacement in SI.
2. Locate the adjuster bar (handle). Determine if the handle pin(s) have come out of the plastic
adjuster block(s).
3. If the pin is in the block, inspect the gap between the adjuster bar and the plastic adjuster blocks.
There should be no space between the two
components.
4. If the pin(s) are out of the block(s) or there is a gap, the adjuster bar needs to be replaced with
the revised part listed below.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-08-50-006 >
Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck > Page 9403
5. Locate and remove the two fasteners that retain the adjuster bar to the inner and outer seat
adjuster assemblies. 6. Remove the adjuster bar. Note that the bar is curved upward at the front.
7. With the adjuster bar removed, inspect the inboard and outboard plastic adjuster blocks for any
damage where the adjuster bar engages into the
holes in the adjuster blocks. If any damage is detected, the affected seat adjuster assembly must
be replaced. The seat adjuster assemblies are available individually (inboard and outboard). Only
replace the component that is damaged. Refer to Manual Seat Adjuster Mechanism Replacement
in SI for replacement procedures.
8. Install the revised adjuster bar. When installing the bar, do not apply pressure to the outer ends
of the bar, it may bend at the pivot mount holes.
Ensure that the curved portion of the bar is in the upward position.
9. With the bar installed, inspect the area where the adjuster bar engages the inboard and outboard
adjuster blocks. Ensure that there is no gap
between the two components.
10. Reinstall the seat. Refer to Front Seat Replacement - Bucket or Split Bench Seat Replacement
in SI.
11. Before tightening the seat mounting bolts, ensure that the inboard and outboard seat tracks are
parallel and spaced 305 mm (12 in) apart as shown. 12. With the seat installed, verify the seat
adjuster function.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-08-50-006 >
Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck > Page 9404
Warranty Information
For vehicles repaired under warranty, use:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-08-50-006 >
Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck > Page 9410
5. Locate and remove the two fasteners that retain the adjuster bar to the inner and outer seat
adjuster assemblies. 6. Remove the adjuster bar. Note that the bar is curved upward at the front.
7. With the adjuster bar removed, inspect the inboard and outboard plastic adjuster blocks for any
damage where the adjuster bar engages into the
holes in the adjuster blocks. If any damage is detected, the affected seat adjuster assembly must
be replaced. The seat adjuster assemblies are available individually (inboard and outboard). Only
replace the component that is damaged. Refer to Manual Seat Adjuster Mechanism Replacement
in SI for replacement procedures.
8. Install the revised adjuster bar. When installing the bar, do not apply pressure to the outer ends
of the bar, it may bend at the pivot mount holes.
Ensure that the curved portion of the bar is in the upward position.
9. With the bar installed, inspect the area where the adjuster bar engages the inboard and outboard
adjuster blocks. Ensure that there is no gap
between the two components.
10. Reinstall the seat. Refer to Front Seat Replacement - Bucket or Split Bench Seat Replacement
in SI.
11. Before tightening the seat mounting bolts, ensure that the inboard and outboard seat tracks are
parallel and spaced 305 mm (12 in) apart as shown. 12. With the seat installed, verify the seat
adjuster function.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-08-50-006 >
Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck > Page 9411
Warranty Information
For vehicles repaired under warranty, use:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc
Player (CD) > Component Information > Service and Repair
Compact Disc Player (CD): Service and Repair
Compact Disc Care and Cleaning
Care of CDs
Handle CDs carefully. Store them in their original cases or other protective cases and away from
direct sunlight and dust. The CD player scans the bottom surface of the disc. If the surface of a CD
is damaged, such as cracked, broken, scratched, or wrinkled labeling, the CD will not play properly
or not at all. If the surface of a CD is soiled, take a soft, lint free cloth or dampen a clean, soft cloth
in a mild, neutral detergent solution mixed with water, and clean it. Make sure the wiping process
starts from the center to the edge. Do not touch the bottom side of a CD while handling it. This
could damage the surface. Pick up CDs by grasping the outer edges or the edge of the hole and
the outer edge.
Care of the CD Player
The use of CD lens cleaners for CD players is not advised, due to the risk of contaminating the
internal lens of the CD optics with lubricants.
Stuck CDs
Interrupting the battery power by pulling the fuse will sometimes release a stuck CD. If a CD is
stuck, and removed, inspect it for warps, cracks, etc. If the CD is damaged, do not replace the
radio.
Labeling CDs
Paper labels can eventually warp and wrinkle, and this will cause the disc to jam inside the CD
player. Try labeling the top of the discs with a soft magic marker instead.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio Receiver > Component Information > Diagrams
Radio Receiver: Diagrams
Component Connector End Views
Digital Radio Receiver (U2K)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R)
Radio/Stereo Noise Filter: Customer Interest Audio System - Noise When Using OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 9428
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R)
Radio/Stereo Noise Filter: All Technical Service Bulletins Audio System - Noise When Using
OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 9434
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering
Wheel Button Activation
Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation
INFORMATION
Bulletin No.: 08-08-44-028
Date: August 28, 2008
Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio
Anomalies
Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior
HUMMER H2, H3 Models 2009 and Prior Saab 9-7X
All Vehicles with Steering Wheel Controls
This bulletin is being issued to provide a recommendation for vehicles with a customer concern of
the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or
radio muting or going silent when driving and turning the steering wheel.
The switches on the right hand side of the steering wheel are easily pressed and may inadvertently
be pressed when turning the steering wheel.
These concerns may be affected by the location of the steering wheel controls.
Recommendation
Do Not Replace The Radio
1. Please determine that the switch controls on the steering wheel are functioning correctly.
2. Ask the customer if their hand was in close proximity to the steering wheel controls when the
condition happened. Explain to the customer that bumping the controls would have caused this
undesired action. Explain to the customer the proper use and function of the steering wheel
controls.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams
Speaker: Diagrams
Component Connector End Views
Speaker - Left Front
Speaker - Left Front Tweeter (UQ2)
Speaker - Left Rear (Extended/Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Page 9442
Speaker - Right Front
Speaker - Right Front Tweeter (UQ2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Page 9443
Speaker - Right Rear (Extended/Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Radio Front Side Door Speaker Replacement
Speaker: Service and Repair Radio Front Side Door Speaker Replacement
Radio Front Side Door Speaker Replacement
Removal Procedure
1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair).
2. Remove the screw securing the speaker to the door. 3. Remove the speaker and the two tabs
from the slots in the door.
4. Disconnect the speaker electrical connector.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Radio Front Side Door Speaker Replacement > Page 9446
1. Connect the speaker electrical connection.
2. Install the two tabs on the speaker into the slots in the door.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the screw securing the speaker to the door.
Tighten the front door speaker screw to 2.5 Nm (22 lb in).
4. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body
and Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Radio Front Side Door Speaker Replacement > Page 9447
Speaker: Service and Repair Radio Rear Side Door Speaker Replacement
Radio Rear Side Door Speaker Replacement
Removal Procedure
1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Body
and Frame/Doors, Hood and Trunk/Doors/Rear
Door/Rear Door Panel/Service and Repair).
2. Remove the screw securing the speaker to the door. 3. Remove the speaker and the two tabs
from the slots in the door.
4. Disconnect the speaker electrical connector.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Radio Front Side Door Speaker Replacement > Page 9448
1. Connect the speaker electrical connection.
2. Install the two tabs on the speaker into the slots in the door.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the screw securing the speaker to the door.
Tighten the rear door speaker screw to 2.5 Nm (22 lb in).
4. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Body
and Frame/Doors, Hood and Trunk/Doors/Rear
Door/Rear Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Relay > Component Information > Locations
Accessory Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams
Alarm Module: Diagrams
Component Connector End Views
Theft Deterrent Module (TDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component
Views
Central Control Module: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Below the I/P Components - 1 of 2
1 - Vehicle Communication Interface Module (VCIM) X1 (UE1) 2 - Vehicle Communication Interface
Module (VCIM) X2 (UE1) 3 - Vehicle Communication Interface Module (VCIM) (UE1) 4 - I/P
Courtesy Lamp - Right 5 - I/P Courtesy Lamp - Left 6 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component
Views > Page 9460
Central Control Module: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component
Views > Page 9461
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 >
Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 >
Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9470
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 >
Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9471
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 >
Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9472
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Communications Control Module: Customer Interest OnStar(R) - Generation 8.0L Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9478
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software
Update
Communications Control Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L
Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software
Update > Page 9484
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to
OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to
OnStar(R) > Page 9489
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to
OnStar(R) > Page 9490
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to
OnStar(R) > Page 9491
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing
Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing
Impaired > Page 9496
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough
When Using OnStar(R)
Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute
Enough When Using OnStar(R)
TECHNICAL
Bulletin No.: 10-08-46-001
Date: January 27, 2010
Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are
Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R)
Customer Service)
Models:
2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009
Saab 9-7X All Equipped with OnStar(R) (RPO UE1)
Condition
Some customers may comment that when the radio is on, it does not mute enough when the
OnStar(R) Turn-by-Turn Navigation directions are announced.
Cause
This condition may be caused by the customer improperly setting the radio volume high enough
when the Turn-by-Turn Navigation messages are played.
The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on
during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can
still be heard at a very low volume. Previous model years initiated a "hard mute" during this
function which completely muted the radio audio.
Correction
Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation
direction announcements. You can control the message volume using the radio volume control,
only when the Turn-by-Turn navigation messages are playing.
Some customers that were accustomed to previous model vehicles with the "hard mute" feature
may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the
OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained
Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the
hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then
create a case number. Advise the customer that the vehicle update should be completed Over the
Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the
customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise
them to press the Blue OnStar(R) Button and ask for Customer Care to check status.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough
When Using OnStar(R) > Page 9501
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Communications Control Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L
Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
> Page 9507
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired >
Page 9512
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When
Using OnStar(R)
Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute
Enough When Using OnStar(R)
TECHNICAL
Bulletin No.: 10-08-46-001
Date: January 27, 2010
Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are
Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R)
Customer Service)
Models:
2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009
Saab 9-7X All Equipped with OnStar(R) (RPO UE1)
Condition
Some customers may comment that when the radio is on, it does not mute enough when the
OnStar(R) Turn-by-Turn Navigation directions are announced.
Cause
This condition may be caused by the customer improperly setting the radio volume high enough
when the Turn-by-Turn Navigation messages are played.
The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on
during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can
still be heard at a very low volume. Previous model years initiated a "hard mute" during this
function which completely muted the radio audio.
Correction
Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation
direction announcements. You can control the message volume using the radio volume control,
only when the Turn-by-Turn navigation messages are playing.
Some customers that were accustomed to previous model vehicles with the "hard mute" feature
may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the
OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained
Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the
hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then
create a case number. Advise the customer that the vehicle update should be completed Over the
Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the
customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise
them to press the Blue OnStar(R) Button and ask for Customer Care to check status.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When
Using OnStar(R) > Page 9517
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) >
Page 9523
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) >
Page 9524
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) >
Page 9525
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired >
Page 9530
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When
Using OnStar(R) > Page 9535
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9536
Communications Control Module: Diagrams
Component Connector End Views
Vehicle Communications Interface Module (VCIM) X1
Vehicle Communications Interface Module (VCIM) X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9537
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9538
Communications Control Module: Service and Repair
Communication Interface Module Replacement
Removal Procedure
Note: The vehicle communication interface module (VCIM) has a specific set of unique numbers
that tie the module to each vehicle. These numbers, the 10-digit station identification (STID) and
the 11-digit electronic serial number (ESN), are used by the National Cellular Network and
OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle
identification number of the vehicle, you must never exchange these parts with those of another
vehicle.
1. Ensure the ignition switch is in the OFF position.
2. Remove the service panel located on the right side of the instrument panel (I/P).
3. Disconnect the VCIM electrical connectors as necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9539
4. Remove the screw retaining the VCIM to the bracket.
5. Release the tab (1) on the bracket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9540
6. Remove the VCIM from the bracket.
7. Remove the VCIM from the vehicle.
Installation Procedure
1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the
labels on the new module.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9541
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the VCIM to the bracket ensuring the retaining tab (1) is fully seated.
Tighten the screw fully driven , seated and not stripped.
3. Connect the VCIM electrical connectors as necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9542
4. Install the service panel.
Note: After replacing the VCIM, you must reconfigure the OnStar(R) system. Failure to reconfigure
the system will result in an additional customer visit for repair. In addition, pressing and holding the
white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will
cause a DTC to set.
5. Reconfigure the OnStar(R) system. Refer to Control Module References (See: Testing and
Inspection/Programming and Relearning). 6. When replacing the communication interface module
be sure to transfer Bluetooth Antenna, if equipped.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 9551
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number
Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
> Page 9557
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference
Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference
Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer
Interest for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software
Update
Global Positioning System Module: Customer Interest OnStar(R) - Generation 8.0L Software
Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer
Interest for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software
Update > Page 9583
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L
Software Update
Global Positioning System Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L
Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L
Software Update > Page 9589
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation
Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Navigation Module: Customer Interest OnStar(R) - Generation 8.0L Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation
Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9598
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Navigation Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update
Navigation Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update
TECHNICAL
Bulletin No.: 08-08-46-008C
Date: January 25, 2011
Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button
Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By
Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record
Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module)
Models:
2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado,
Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3
2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1)
Attention:
This bulletin is being issued to provide the dealer with information regarding a condition pertaining
to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect
the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform
certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free
calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R).
Supercede: This bulletin is being revised to update the correction information. Please discard
Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories).
Condition
Note
Performing this procedure will clear out all of the customers nametags stored in the VCIM. These
will need to be restored by the customer once the procedures are completed.
Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar
system may report some of the following concerns:
- No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may
also have a battery drain.
- Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle.
- Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the
nametag may be present but the customer is unable to use it or delete it.
- The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes)
plan but when trying to use OHFC they receive a message that there are insufficient units.
- OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn
honk, light flash).
- Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor
that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display
information in their vehicle.
- The "Virtual Advisor" command may not be available or will not access the system for eNav
routes that have been stored through MapQuest(R).
- In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls
to the OnStar(R) center.
- No GPS location when calling into OnStar(R).
- Unable to access the Advisor Record feature.
Cause
These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be
corrected through a software update using the Service Programming System (SPS) application.
Correction
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Navigation Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9604
Customer Notification
OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters
will include a reference to this bulletin. Some customers may also be referred to the dealer by
either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following
attempts to resolve any of the listed concerns.
Dealer Action
If any or all of the above conditions have been met, dealer technicians should reprogram the
OnStar(R) VCIM. A revised service calibration has been released to address this condition.
Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS)
application.
Notice
After the programming, perform the following steps to clear the old nametags from the system that
may not be working.
1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2.
Change the language setting to either French or Spanish and save. Then power off the vehicle. 3.
Power up the vehicle and change the language setting back to English and save. Then power off
the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button
assembly. After the "Ready" prompt, reply "delete all nametags."
Note
Always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules
Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9613
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9614
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9615
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules
Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control
Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9621
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9622
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9623
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's
Set By Various Control Modules
Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's
Set By Various Control Modules > Page 9632
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's
Set By Various Control Modules > Page 9633
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's
Set By Various Control Modules > Page 9634
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules
Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control
Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 9640
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 9641
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 9642
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent
Steering Wheel Button Activation
Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation
INFORMATION
Bulletin No.: 08-08-44-028
Date: August 28, 2008
Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio
Anomalies
Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior
HUMMER H2, H3 Models 2009 and Prior Saab 9-7X
All Vehicles with Steering Wheel Controls
This bulletin is being issued to provide a recommendation for vehicles with a customer concern of
the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or
radio muting or going silent when driving and turning the steering wheel.
The switches on the right hand side of the steering wheel are easily pressed and may inadvertently
be pressed when turning the steering wheel.
These concerns may be affected by the location of the steering wheel controls.
Recommendation
Do Not Replace The Radio
1. Please determine that the switch controls on the steering wheel are functioning correctly.
2. Ask the customer if their hand was in close proximity to the steering wheel controls when the
condition happened. Explain to the customer that bumping the controls would have caused this
undesired action. Explain to the customer the proper use and function of the steering wheel
controls.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket >
Component Information > Service and Repair
Towing Hook / Bracket: Service and Repair
Tow Hook Replacement
Removal Procedure
1. Remove the front bumper. Refer to Front Bumper Replacement (See: Body and
Frame/Bumper/Front Bumper/Service and Repair).
2. Remove the right tow hook nuts and bolts from the frame rail. 3. Remove the right tow hook from
the vehicle.
4. Remove the left tow hook nuts and bolts from the frame rail. 5. Remove the left tow hook from
the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket >
Component Information > Service and Repair > Page 9652
1. Install the left tow hook to the frame rail.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the nuts and the bolts to the frame rail and tighten the bolts to 100 Nm (74 lb ft).
3. Install the left tow hook to the frame rail. 4. Install the nuts and the bolts to the frame rail and
tighten the bolts to 100 Nm (74 lb ft). 5. Install the front bumper. Refer to Front Bumper
Replacement (See: Body and Frame/Bumper/Front Bumper/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams
Trailer Connector: Diagrams
Component Connector End Views
Trailer Connector (UY7)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch >
Component Information > Service and Repair
Trailer Hitch: Service and Repair
Trailer Weight Distributor Hitch Platform Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module >
Component Information > Service and Repair
Trailer Lighting Module: Service and Repair
Trailer Lamp Control Module Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams
Trailer Connector: Diagrams
Component Connector End Views
Trailer Connector (UY7)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Customer Interest: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After
Start Up
Body Control Module: Customer Interest Body Controls - Security Lamp ON After Start Up
TECHNICAL
Bulletin No.: 09-08-56-001
Date: March 12, 2009
Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs
(Reprogram BCM)
Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T
Note
The information contained in this bulletin applies to vehicles located in the U.S. only.
Condition
Some customers may comment that the Security Light remains illuminated after the vehicle has
started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and
Engine Control Module (ECM).
Cause
This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run"
and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM
sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the
"Crank" mode to turn the light off.
Correction
Important Do Not replace the ignition switch for this concern.
1. Verify the customer concern.
2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI.
3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the
latest software available on TIS2WEB. Refer to the
Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with
the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp
ON After Start Up
Body Control Module: All Technical Service Bulletins Body Controls - Security Lamp ON After Start
Up
TECHNICAL
Bulletin No.: 09-08-56-001
Date: March 12, 2009
Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs
(Reprogram BCM)
Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T
Note
The information contained in this bulletin applies to vehicles located in the U.S. only.
Condition
Some customers may comment that the Security Light remains illuminated after the vehicle has
started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and
Engine Control Module (ECM).
Cause
This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run"
and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM
sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the
"Crank" mode to turn the light off.
Correction
Important Do Not replace the ignition switch for this concern.
1. Verify the customer concern.
2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI.
3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the
latest software available on TIS2WEB. Refer to the
Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with
the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof
Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Water leaks/ Wind Noise
From The Sunroof
TECHNICAL
Bulletin No.: 07-08-67-001B
Date: June 22, 2009
Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and
Apply Sealer)
Models:
2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof
Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate
Bulletin 07-08-67-001A (Section 08 - Body & Accessories).
Condition
Some customers may comment on water entering into the vehicle from the sunroof area. Other
customers may comment on a wind noise or whistle noise heard from the sunroof area when
driving at different speeds.
Design
The sunroof module is designed to be completely sealed at the roof panel to help prevent water
from traveling past the glass panel seal. The sunroof glass assembly does not have any glass
panel adjustments. The sunroof assembly does not contain a water management drain tube
system. When operating the sunroof, the glass panel moves rearward and slides up above the roof
panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove
excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some
water may enter inside the vehicle.
Cause
Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the
upper sunroof frame assembly.
Wind or Whistle Noise Test Procedure
Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI.
Water Hose Test Procedure
Perform a water hose test to determine where the leak is entering the sunroof assembly.
Important Use a water hose without the nozzle attached at a controlled medium volume water flow.
1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1)
like in the graphic above is not flush, make sure
no parts are broken or missing from the sunroof module assembly.
2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with
warm water to clean the seals. Use GM(TM) Glass
Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks.
3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open
position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6.
Remove the outer trim cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9685
7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8.
Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water
test to verify the leak concern.
10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of
the following four areas:
1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be
entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the
sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip
holder.
11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire
outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking
tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one
inch of tape at a time until the source of the leak can be
pinpointed.
14. Proceed with the water test while removing the masking tape along the right front outer sunroof
frame and roof panel until the complete area has
been tested.
15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame
with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start
water testing while removing the masking tape from the left front corner of the sunroof glass; then
proceed along to the right front corner of
the glass until the complete area has been tested.
18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing
and mark the entry point of the water. 20. The leak could be from more than one area, so
determine which conditions apply and follow the recommended corrections below.
Condition 1
The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof
frame.
Cause 1
The dry foam seal on the upper sunroof frame assembly may have collapsed or has become
distorted, causing the leak.
Correction 1
Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to
the outer edge of the upper sunroof frame using the procedure listed below:
1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI.
Important Note the size, color and locations of the lower sunroof frame screws when removing
them.
2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame.
Important Do Not remove the (red) TORX(R) screws from the track.
3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower
frame from the sunroof module assembly.
Important Have a clean workbench with a flat protective cover. The cover will help protect the
sunroof glass when the glass is placed face down on the bench.
5. Remove the sunroof module and window from the vehicle and place the glass side down on a
clean bench.
Tip The sunroof window can now be manually moved forward or backward.
6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of
the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the
sunroof frame. If the
sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9686
8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if
no adhesive has been used. If adhesive has been
used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner,
P/N 08984, or equivalent, to clean the roof panel.
9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare
edges of the roof panel opening for the sunroof
module. This grease is recommended for use on any bare edges around the sunroof opening. An
acid brush can be used to apply the grease.
10. A caulk gun applicator will be needed to apply the adhesive (1).
Tip You may want to use some disposable gloves to keep the adhesive from getting onto your
hands.
11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame
assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install
the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame
assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Manually push the sunroof window to the full open position. This will allow the window, motors
and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement
in SI. 18. Verify the proper operation of the sunroof.
19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade
while using a 3M(TM) General Purpose Cleaner,
P/N 08984, or equivalent, as shown in the graphic above.
20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover.
Refer to Sunroof Front Trim Cover Replacement in SI.
Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open
the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are
installed properly.
22. Install the outer trim cover and four screws.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9687
Tighten Tighten the screws to 1 Nm (9 lb in).
Condition 2
A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the
window weather seal (4).
Cause 2
The seal on the upper sunroof frame assembly may not have enough sealant under the seal.
Correction 2
Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip
sealing flange located in the upper sunroof frame.
Condition 3
A leak from the sunroof window glass and sunroof window seal.
Cause 3
The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass
to seal properly.
Correction 3
Replace the sunroof window seal following the steps below:
1. Open the sunshade to the full open position.
2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal
Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9688
Condition 4
A leak from around the sunroof glass holder clip, known as a "blow out clip" (1).
Cause 4
A lack of adhesive sealant under the sunroof window holder clip.
Correction 4
Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the
upper frame clip using the steps below.
1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove
the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two
screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the
two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to
the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws.
Tighten Tighten the two screws to 1 Nm (9 lb in).
Important The chamfered edge of the gear goes toward the motor when reinstalling the gear.
10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws.
Tighten Tighten the screw to 2 Nm (18 lb in).
13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install
the sunroof motor assembly. 15. Install the sunroof motor screws and tighten.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim
cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and
four screws.
Tighten Tighten the screws to 1 Nm (9 lb in).
Waterleak Odor in Vehicle
Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles.
Dry out any wet components. Refer to Floor Carpet Drying in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9689
Parts Information
To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144
from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to
place orders. The dealer also has the option to complete a referral request form to purchase the
product through a local supplier.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9695
7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8.
Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water
test to verify the leak concern.
10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of
the following four areas:
1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be
entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the
sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip
holder.
11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire
outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking
tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one
inch of tape at a time until the source of the leak can be
pinpointed.
14. Proceed with the water test while removing the masking tape along the right front outer sunroof
frame and roof panel until the complete area has
been tested.
15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame
with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start
water testing while removing the masking tape from the left front corner of the sunroof glass; then
proceed along to the right front corner of
the glass until the complete area has been tested.
18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing
and mark the entry point of the water. 20. The leak could be from more than one area, so
determine which conditions apply and follow the recommended corrections below.
Condition 1
The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof
frame.
Cause 1
The dry foam seal on the upper sunroof frame assembly may have collapsed or has become
distorted, causing the leak.
Correction 1
Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to
the outer edge of the upper sunroof frame using the procedure listed below:
1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI.
Important Note the size, color and locations of the lower sunroof frame screws when removing
them.
2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame.
Important Do Not remove the (red) TORX(R) screws from the track.
3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower
frame from the sunroof module assembly.
Important Have a clean workbench with a flat protective cover. The cover will help protect the
sunroof glass when the glass is placed face down on the bench.
5. Remove the sunroof module and window from the vehicle and place the glass side down on a
clean bench.
Tip The sunroof window can now be manually moved forward or backward.
6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of
the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the
sunroof frame. If the
sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9696
8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if
no adhesive has been used. If adhesive has been
used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner,
P/N 08984, or equivalent, to clean the roof panel.
9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare
edges of the roof panel opening for the sunroof
module. This grease is recommended for use on any bare edges around the sunroof opening. An
acid brush can be used to apply the grease.
10. A caulk gun applicator will be needed to apply the adhesive (1).
Tip You may want to use some disposable gloves to keep the adhesive from getting onto your
hands.
11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame
assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install
the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame
assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Manually push the sunroof window to the full open position. This will allow the window, motors
and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement
in SI. 18. Verify the proper operation of the sunroof.
19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade
while using a 3M(TM) General Purpose Cleaner,
P/N 08984, or equivalent, as shown in the graphic above.
20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover.
Refer to Sunroof Front Trim Cover Replacement in SI.
Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open
the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are
installed properly.
22. Install the outer trim cover and four screws.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9697
Tighten Tighten the screws to 1 Nm (9 lb in).
Condition 2
A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the
window weather seal (4).
Cause 2
The seal on the upper sunroof frame assembly may not have enough sealant under the seal.
Correction 2
Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip
sealing flange located in the upper sunroof frame.
Condition 3
A leak from the sunroof window glass and sunroof window seal.
Cause 3
The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass
to seal properly.
Correction 3
Replace the sunroof window seal following the steps below:
1. Open the sunshade to the full open position.
2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal
Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9698
Condition 4
A leak from around the sunroof glass holder clip, known as a "blow out clip" (1).
Cause 4
A lack of adhesive sealant under the sunroof window holder clip.
Correction 4
Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the
upper frame clip using the steps below.
1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove
the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two
screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the
two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to
the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws.
Tighten Tighten the two screws to 1 Nm (9 lb in).
Important The chamfered edge of the gear goes toward the motor when reinstalling the gear.
10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws.
Tighten Tighten the screw to 2 Nm (18 lb in).
13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install
the sunroof motor assembly. 15. Install the sunroof motor screws and tighten.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim
cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and
four screws.
Tighten Tighten the screws to 1 Nm (9 lb in).
Waterleak Odor in Vehicle
Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles.
Dry out any wet components. Refer to Floor Carpet Drying in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9699
Parts Information
To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144
from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to
place orders. The dealer also has the option to complete a referral request form to purchase the
product through a local supplier.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Harness Routing Views
Body Control Module: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Harness Routing Views > Page 9702
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Harness Routing Views > Page 9703
15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Harness Routing Views > Page 9704
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312
(Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp
(CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to
LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer
Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300
17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC
Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint
Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210
(A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control
Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to
Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Harness Routing Views > Page 9705
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Harness Routing Views > Page 9706
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Harness Routing Views > Page 9707
Body Control Module: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Right Kick Panel Components
1 - Body Harness 2 - Instrument Panel Harness 3 - Body Control Module (BCM) 4 - X201 5 - Body
Control Module (BCM) X2 6 - Body Control Module (BCM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Page 9708
Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Page 9709
Body Control Module (BCM) X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Page 9710
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Page 9711
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Page 9712
Body Control Module: Service and Repair
Body Control Module Replacement
Removal Procedure
Important:
* The ignition switch should be in the OFF position when connecting or disconnecting the
connectors to the body control module (BCM).
* Always disconnect the black body wiring harness connector FIRST and the gray instrument panel
(I/P) wiring harness connector LAST.
* Always connect the black body wiring harness connector FIRST and the gray I/P wiring harness
LAST.
* Do not open the BCM housing. The module does not have any serviceable components. The
module may be replaced only as an assembly.
1. Ensure the ignition switch is in the OFF position. 2. Remove the right front hinge pillar trim panel.
Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Interior Moulding /
Trim/Trim Panel/Service and Repair).
3. Disconnect the body wiring harness electrical connector (1) from the BCM.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Page 9713
4. Disconnect the I/P wiring harness electrical connector (1) from the BCM.
5. Release the fastener retaining the body wiring harness electrical connector to the BCM.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Page 9714
6. Remove the 2 fasteners retaining the BCM to the hinge pillar. 7. Remove the BCM from the
hinge pillar by unlocking the integral tab. 8. Remove the BCM from the vehicle.
Installation Procedure
1. Position the BCM to the vehicle. 2. Attach the BCM to the hinge pillar with the integral tab. 3.
Install the 2 fasteners retaining the BCM to the hinge pillar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Page 9715
4. Install the fastener retaining the body wiring harness electrical connector to the BCM.
5. Connect the body wiring harness electrical connector (1) to the BCM.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Locations > Page 9716
6. Connect the I/P wiring harness electrical connector (1) to the BCM. 7. Install the right front hinge
pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Interior
Moulding /
Trim/Trim Panel/Service and Repair).
8. If installing a replacement BCM, program the BCM. Refer to Control Module References (See:
Testing and Inspection/Programming and
Relearning).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting
Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to
Painting
INFORMATION
Bulletin No.: 08-08-51-002
Date: March 12, 2008
Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation
Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3
The purpose of this bulletin is to inform the technician that General Motors has made a change in
the primer it uses for TPO plastic for service parts. This new primer comes in several different
colors from five different suppliers. This change affects the cleaning process of the painting
operation. The new process is as follows.
1. Wash with soap and water.
2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your
paint supplier for product recommendations.
3. Scuff sand per your paint suppliers recommendations.
Note:
The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not
have any affect on this primer.
4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner).
All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You
may find other TPO parts with this primer. If the technician has a question as to the type of plastic
they are painting, inspect the back of the part for the plastic symbol (TPO).
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Front Bumper Fascia Replacement
Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Replacement
Front Bumper Fascia Replacement (Canyon/Colorado)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the front bumper (1) assembly. Refer
to Front Bumper Replacement (See: Service and Repair). 3. Remove the push-pins retaining the
fascia (2) to the front bumper. 4. Pull the fascia straight forward to remove.
Installation Procedure
1. Install the fascia (2) to the front bumper. 2. Install the push-pins retaining the fascia to the front
bumper.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Front Bumper Fascia Replacement > Page 9725
3. Install the front bumper (1) assembly. Refer to Front Bumper Replacement (See: Service and
Repair). 4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Front Bumper Fascia Replacement > Page 9726
Front Bumper Cover / Fascia: Service and Repair Front Bumper Lower Fascia Trim Insert Grille
Replacement
Front Bumper Lower Fascia Trim Insert Grille Replacement (Colorado)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System
Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting
Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to
Painting
INFORMATION
Bulletin No.: 08-08-51-002
Date: March 12, 2008
Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation
Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3
The purpose of this bulletin is to inform the technician that General Motors has made a change in
the primer it uses for TPO plastic for service parts. This new primer comes in several different
colors from five different suppliers. This change affects the cleaning process of the painting
operation. The new process is as follows.
1. Wash with soap and water.
2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your
paint supplier for product recommendations.
3. Scuff sand per your paint suppliers recommendations.
Note:
The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not
have any affect on this primer.
4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner).
All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You
may find other TPO parts with this primer. If the technician has a question as to the type of plastic
they are painting, inspect the back of the part for the plastic symbol (TPO).
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System
Information > Service and Repair > Rear Bumper Impact Bar Replacement
Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Replacement
Rear Bumper Impact Bar Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System
Information > Service and Repair > Rear Bumper Impact Bar Replacement > Page 9736
Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Reinforcement
Replacement
Rear Bumper Impact Bar Reinforcement Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System
Information > Service and Repair > Rear Bumper Impact Bar Replacement > Page 9737
Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Brace Replacement
Rear Bumper Impact Bar Brace Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System
Information > Service and Repair > Rear Bumper Impact Bar Replacement > Page 9738
Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Bracket Replacement
Rear Bumper Impact Bar Bracket Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair
Cabin Ventilation Grille: Service and Repair
Pressure Relief Valve Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and
Repair
Cowl Moulding / Trim: Service and Repair
Air Inlet Grille Panel Replacement
Removal Procedure
1. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper
and Washer Systems/Wiper Arm/Service and
Repair).
2. Remove the air inlet grill panel push-pin retainers. 3. Disconnect the washer hose. 4. Remove
the air inlet grille panel from the vehicle.
Installation Procedure
1. Position the air inlet grille panel to the vehicle. 2. Connect the washer hose.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and
Repair > Page 9746
3. Install the push-pin retainers. 4. Install the windshield wiper arms. Refer to Windshield Wiper
Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle >
Front Door Exterior Handle > System Information > Service and Repair
Front Door Exterior Handle: Service and Repair
Front Side Door Outside Handle Replacement
Removal Procedure
1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front
Door Panel/Service and Repair). 2. Remove the front door water deflector. Refer to Front Side
Door Water Deflector Replacement (See: Front Door Panel/Service and Repair). 3. Disconnect the
outside door handle rod by releasing the retaining clip (2). 4. Disconnect the lock cylinder rod by
releasing the retaining clip (1).
5. Remove the bolts retaining the outside door handle to the door. 6. Remove the outside door
handle from the door. 7. Remove the lock cylinder from the outside door handle. Refer to Front
Side Door Lock Cylinder Replacement (See: Locks/Door Locks/Door
Lock Cylinder/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle >
Front Door Exterior Handle > System Information > Service and Repair > Page 9754
Installation Procedure
1. Install the lock cylinder to the outside door handle. Refer to Front Side Door Lock Cylinder
Replacement (See: Locks/Door Locks/Door Lock
Cylinder/Service and Repair).
2. Install the outside door handle to the front door.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the bolts retaining the outside door handle to the door.
Tighten the outside door handle bolts to 9 Nm (80 lb in).
4. Connect the lock cylinder rod to the lock cylinder using the retaining clip (1). 5. Connect the
outside door handle rod to the door handle using the retaining clip (2). 6. Install the front door water
deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service
and Repair). 7. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement
(See: Front Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle >
Front Door Interior Handle > System Information > Service and Repair
Front Door Interior Handle: Service and Repair
Front Side Door Inside Handle Replacement
Removal Procedure
1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front
Door Panel/Service and Repair). 2. Remove the water deflector. Refer to Front Side Door Water
Deflector Replacement (See: Front Door Panel/Service and Repair). 3. Slide the inside door handle
rearward to release the retaining tabs (1) from the door inner panel.
4. Remove the lock cables from the inside door handle. 5. Remove the inside door handle from the
door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle >
Front Door Interior Handle > System Information > Service and Repair > Page 9758
1. Install the lock cables to the inside door handle.
2. Insert the inside door handle retaining tabs (1) into the slots of the door inner panel. 3. Slide the
inside door handle forward until the door handle retainers are fully engaged. 4. Install the water
deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service
and Repair). 5. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement
(See: Front Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge >
System Information > Service and Repair > Front Side Door Hinge Replacement - Body Side
Front Door Hinge: Service and Repair Front Side Door Hinge Replacement - Body Side
Front Side Door Hinge Replacement - Body Side
Removal Procedure
1. Open the front door. 2. Remove the bolt retaining the front door check link to the body. 3.
Remove the front door wiring harness grommet from the body, and disconnect the door wiring
harness connectors. Refer to Front Side Door
Wiring Harness Replacement (See: Service and Repair).
4. Remove the bolts (1) retaining the front door hinge keeper straps. 5. With an assistant, lift the
front door up off the body side hinges, and place on a clean protected surface.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge >
System Information > Service and Repair > Front Side Door Hinge Replacement - Body Side > Page 9763
6. Clean the mounting surfaces of the body side hinges with a clean rag, and mark the front door
hinge locations with a grease pencil, or other
suitable marker.
7. Remove the bolts retaining the body side hinges to the body. 8. Remove the hinges from the
body.
Installation Procedure
1. Position the body side front door hinge to the alignment marks.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the body side door hinge to the body and tighten to 27 Nm (20 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge >
System Information > Service and Repair > Front Side Door Hinge Replacement - Body Side > Page 9764
3. With an assistant, lower the front door down onto the body side hinge straps. 4. Install the bolts
(1) retaining the front door hinge keeper straps and tighten to 25 Nm (18.4 lb ft). 5. Connect the
front door wiring harness connectors, and install the front door wiring harness grommet to the body.
Refer to Front Side Door Wiring
Harness Replacement (See: Service and Repair).
6. Install the bolt retaining the front door check link to the body and tighten to 25 Nm (18.4 lb ft). 7.
Inspect the door for proper operation and alignment. Refer to Front Side Door Adjustment (See:
Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge >
System Information > Service and Repair > Front Side Door Hinge Replacement - Body Side > Page 9765
Front Door Hinge: Service and Repair Front Side Door Hinge Replacement - Door Side
Front Side Door Hinge Replacement - Door Side
Removal Procedure
1. Open the front door. 2.
Remove the bolt retaining the front door check link to the body.
3. Remove the front door wiring harness grommet from the body and disconnect the door wiring
harness connectors. Refer to Front Side Door
Wiring Harness Replacement (See: Service and Repair).
4. Remove the bolts (1) retaining the front door hinge keeper straps. 5. With the aid of an assistant,
lift the front door up off the body side hinges and place the door on a clean, protected surface.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge >
System Information > Service and Repair > Front Side Door Hinge Replacement - Body Side > Page 9766
6. Remove the bolts retaining the door side hinges to the door. 7. Remove the hinges from the
door.
Installation Procedure
1. Position the door side front door hinge to the door.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the door side door hinge to the door and tighten to 27 Nm (20 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge >
System Information > Service and Repair > Front Side Door Hinge Replacement - Body Side > Page 9767
3. With the aid of an assistant, lower the front door down onto the body side hinge straps. 4. Install
the bolts (1) retaining the front door hinge keeper straps and tighten to 25 Nm (18 lb ft). 5. Connect
the front door wiring harness connectors and install the front door wiring harness grommet to the
body. Refer to Front Side Door Wiring
Harness Replacement (See: Service and Repair).
6. Install the bolt retaining the front door check link to the body and tighten to 25 Nm (18 lb ft). 7.
Inspect the door for proper operation and alignment. Refer to Front Side Door Adjustment (See:
Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter >
System Information > Service and Repair
Front Door Limiter: Service and Repair
Front Side Door Check Link Replacement
Removal Procedure
1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front
Door Panel/Service and Repair). 2. Remove the front door water deflector. Refer to Front Side
Door Water Deflector Replacement (See: Front Door Panel/Service and Repair).
3. Remove the bolt retaining the front door check link to the body.
4. Remove the nuts retaining the front door check link to the door. 5. Remove the front door check
link (1) from the door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter >
System Information > Service and Repair > Page 9771
1. Install the front door check link to the door, ensuring the alignment mark (1) faces upward.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the nuts retaining the front door check link to the door and tighten to 9 Nm (80 lb in).
3. Install the bolt retaining the front door check link to the body and tighten to 25 Nm (18.4 lb ft). 4.
Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See:
Front Door Panel/Service and Repair). 5. Install the front door trim panel. Refer to Front Side Door
Trim Panel Replacement (See: Front Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel >
System Information > Service and Repair > Front Side Door Trim Panel Replacement
Front Door Panel: Service and Repair Front Side Door Trim Panel Replacement
Front Side Door Trim Panel Replacement
Special Tools
J 9886-01 Door Handle Clip Remover
Removal Procedure
1. Remove the window regulator handle from the door by inserting tool J 9886-01 between the
handle and the white plastic washer to remove the
retaining clip, if the vehicle is equipped with manual windows.
2. Remove the retaining screw from the door handle bezel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel >
System Information > Service and Repair > Front Side Door Trim Panel Replacement > Page 9776
3. Remove the 2 retaining screws from the armrest and lift the front of the switch plate to disengage
the clip.
4. Disconnect the electrical harness (3-4) from the power window switch (2, 5), if equipped. 5.
Remove the upper trim cover from the door.
6. Gently pull the door panel away from the door. 7. Remove any fasteners from the door and
reinsert them in the door panel before installing the panel on the door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel >
System Information > Service and Repair > Front Side Door Trim Panel Replacement > Page 9777
1. Install the trim panel to the door, ensuring that all the retaining tabs are fully seated.
2. Connect the electrical harness (3-4) to the power window switch (2, 5), if equipped.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel >
System Information > Service and Repair > Front Side Door Trim Panel Replacement > Page 9778
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the 2 retaining screws in the switch plate. Tighten the front door switch plate screws to 2
Nm (18 lb in).
4. Install the retaining screw in the door handle bezel. Tighten the front door handle bezel screws to
2 Nm (18 lb in). 5. Install the window regulator handle from the door and insert the clip between the
handle and the white plastic washer, if the vehicle is equipped
with manual windows.
6. Install the upper trim cover to the door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel >
System Information > Service and Repair > Front Side Door Trim Panel Replacement > Page 9779
Front Door Panel: Service and Repair Front Side Door Water Deflector Replacement
Front Side Door Water Deflector Replacement
Removal Procedure
1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: ). 2.
Remove the front door water deflector from the front door inner panel. 3. Pull the electrical
connectors through the slit in the water deflector.
Installation Procedure
1. Align the front door water deflector to the front door inner panel. Secure the water deflector at
the corners. 2. Pull the front door electrical connectors through the slit in the water deflector. 3.
Install the front door water deflector. Start pressing the adhesive pattern at the bottom center and
working outward and upward in order to prevent
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel >
System Information > Service and Repair > Front Side Door Trim Panel Replacement > Page 9780
puckering.
4. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker >
System Information > Adjustments
Front Door Striker: Adjustments
Door Lock Striker Adjustment
1. Ensure that the door is properly aligned within the door opening before proceeding with the
striker adjustment. Refer to Front Side Door
Adjustment (See: Adjustments) and Rear Door Adjustment (See: Rear Door/Adjustments).
2. Close the door onto the striker and note if the door drags on the striker causing the door to move
upward or downward upon contact with the
striker. Also note closing effort to fully engage the latch.
3. Mark the position of the door striker with a grease pencil. 4. Loosen the screws retaining the
door striker to the body. 5. Move the striker to eliminate drag on the striker and door latch and to
achieve the proper door position within the door opening. Start with the
up/down position, then position the striker to achieve proper alignment to the door opening. Set the
in/out adjustment for the proper door seal engagement ensuring that the door closing efforts are
correct.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Tighten the screws retaining the door striker to the body.
Tighten the door striker screws to 25 Nm (18 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker >
System Information > Adjustments > Page 9784
Front Door Striker: Service and Repair
Door Striker Replacement
Removal Procedure
1. Mark the position of the door striker with a grease pencil. 2. Remove the screw retaining the door
striker to the body. 3. Remove the door striker from the body.
Installation Procedure
1. Install the door striker to the body. 2. Align the lock striker to the alignment marks.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker >
System Information > Adjustments > Page 9785
3. Install the door striker screws to the body.
Tighten the door striker screws to 25 Nm (18 lb ft).
4. Adjust the lock striker if required. Refer to Door Lock Striker Adjustment (See: Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip
> Component Information > Service and Repair > Auxiliary Weatherstrip Replacement
Front Door Weatherstrip: Service and Repair Auxiliary Weatherstrip Replacement
Auxiliary Weatherstrip Replacement
Crew cab shown, others similar.
Removal Procedure
1. Open the front and rear door, as necessary. 2. Remove the auxiliary weatherstrip by pulling the
weatherstrip (1) from the roof pinchweld flange (2).
Installation Procedure
1. Install the auxiliary weatherstrip to the roof pinchweld flange by pressing the weatherstrip (1)
onto the roof flange (2), until it is fully seated. 2. Close the front and rear door, as necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip
> Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9790
Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement
(Extended)
Front Door Opening Weatherstrip Replacement (Extended)
Removal Procedure
1. Open the front and rear door. 2. Remove the front door opening weatherstrip (1) from the
opening pinchweld flange. 3. Remove the front door opening weatherstrip from the vehicle.
Installation Procedure
1. Align the paint dot on the front door weatherstrip to the notch (2) in the upper rear corner of the
pitchweld flange. 2. Starting at the notch (2) in the upper rear corner, press the front door opening
weatherstrip (1) onto the pinchweld flange until it is fully seated. 3. Pull the cord (3) on the front
door opening weatherstrip, ensuring the weatherstrip lip overlaps the interior trim panels and
headliner.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip
> Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9791
4. Close the front door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip
> Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9792
Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement
(Regular, Crew)
Front Door Opening Weatherstrip Replacement (Regular, Crew)
Removal Procedure
1. Open the front door. 2. Remove the lower center pillar panel. Refer to Center Pillar Lower Trim
Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service
and Repair).
3. Remove the front door opening weatherstrip (2) from the door opening pinchweld flange (1). 4.
Remove the front door opening weatherstrip from the vehicle.
Installation Procedure
1. Position the front door opening weatherstrip to the pinchweld flange.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip
> Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9793
2. Starting at the upper rear corner, press the front door opening weatherstrip (2) onto the
pinchweld flange (1) until it is fully seated. 3. Install the lower center pillar panel. Refer to Center
Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and
Repair).
4. Pull the cord (3) on the front door opening weatherstrip ensuring the weatherstrip lip overlaps the
interior trim panels and headliner. 5. Close the front door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip
> Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9794
Front Door Weatherstrip: Service and Repair Front Side Door Weatherstrip Replacement
(Extended)
Front Side Door Weatherstrip Replacement (Extended)
Tools Required
J 38778 Door Trim Pad Clip Remover or Equivalent
Removal Procedure
1. Open the front door. 2. Remove the upper weatherstrip mold from the door by removing the
integral weatherstrip pushpin (2) from the door using J 38778 , or
equivalent.
3. Remove the lower weatherstrip mold from the door removing the integral weatherstrip pushpin
(3) from the door using J 38778 , or equivalent. 4. Remove the weatherstrip from around the door
by inserting J 38778 , or equivalent, under the weatherstrip (1), and releasing the integral retainers
from the door frame.
5. Remove the weatherstrip from the door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip
> Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9795
1. Position the weatherstrip to the front door. 2. Install the upper weatherstrip mold to the door
using the integral weatherstrip pushpin (2). 3. Install the lower weatherstrip mold to the door using
the integral weatherstrip pushpin (3). 4. Install the weatherstrip around the front door frame using
the integral retainers. 5. Close the front door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip
> Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9796
Front Door Weatherstrip: Service and Repair Front Side Door Weatherstrip Replacement (Regular,
Crew)
Front Side Door Weatherstrip Replacement (Regular, Crew)
Tools Required
J 38778 Door Trim Pad Clip Remover or Equivalent
Removal Procedure
1. Open the front door. 2. Remove the weatherstrip from around the door by inserting J 38778 , or
equivalent , under the weatherstrip (1) and releasing the integral retainers
from the door frame.
3. Remove the weatherstrip from the front door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip
> Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9797
1. Position the weatherstrip to the front door. 2. Install the weatherstrip around the front door frame
using the integral retainers. 3. Close the front door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > Customer Interest: > 09-08-64-013A > May > 09 > Body - Front
Door Glass Inoperative/Binding/Rattling
Front Door Window Glass: Customer Interest Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > Customer Interest: > 09-08-64-013A > May > 09 > Body - Front
Door Glass Inoperative/Binding/Rattling > Page 9806
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > Customer Interest: > 09-08-64-013A > May > 09 > Body - Front
Door Glass Inoperative/Binding/Rattling > Page 9807
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: >
00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information
Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion
Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: >
06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information
Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping
Information
INFORMATION
Bulletin No.: 06-08-64-001B
Date: October 20, 2009
Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock
Box
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add vehicles and model years and to include all types of
door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body &
Accessories).
- In several warranty parts review cases, side door window glass was observed with a chip or chips
on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box
on the front side door window glass.
- A random selection of side door glass returns will be conducted to confirm adherence. If a side
door glass is discovered with a chip or chips in the location previously described, the side door
glass will be returned to the dealership for debit.
Example of Side Door Glass
- DO NOT place a vehicle key lock box on a side door window glass.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: >
06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information > Page 9817
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: >
09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling
Front Door Window Glass: All Technical Service Bulletins Body - Front Door Glass
Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: >
09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9822
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: >
09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9823
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: >
08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start
Fuse: All Technical Service Bulletins Electrical - Dead Battery/No Crank/No Start
TECHNICAL
Bulletin No.: 08-06-03-010
Date: September 30, 2008
Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC)
Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System
Message (Install 125 Amp Mega Fuse)
Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3
Condition
Some customers may comment on the following conditions:
^ The battery runs down.
^ The engine will not crank.
^ The engine will not start.
^ The Instrument Panel Cluster charge indicator turns on.
^ The Driver Information Center displays a Service Charge System message.
Cause
This condition may be caused by an open Mega Fuse in the underhood electrical center.
Correction
Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new
Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently
has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: >
08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start > Page 9829
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: >
Page 9830
Front Door Window Glass: By Symptom
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: >
Page 9831
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: >
Page 9832
Disclaimer
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: >
Page 9833
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: >
Page 9834
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: >
Page 9835
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: >
Page 9836
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: >
Page 9837
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: >
Page 9838
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > Page 9839
Front Door Window Glass: Service and Repair
Front Side Door Window Replacement
Removal Procedure
1. Position the front door window approximately halfway down. 2. Remove the front door trim panel.
Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair). 3.
Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement
(See: Front Door Panel/Service and Repair). 4. Remove the front door outer belt sealing strip.
Refer to Front Side Door Window Belt Outer Sealing Strip Replacement (See: Windows and
Glass/Windows/Service and Repair/Front Side Door Window Belt Outer Sealing Strip
Replacement).
5. Remove the bolts retaining the front door window to the window regulator.
6. Lift the window off of the window regulator. 7. Rotate the rear of the window upwards,
disengaging the window from the window run channel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > Page 9840
8. Remove the window from between the inner and outer door panels.
Installation Procedure
1. Install the front door window into the front door between the inner and outer door panels. 2.
Rotate the rear of the window down, positioning the window into the window run channels. 3. Lower
the window down onto the window regulator.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the bolts retaining the front door window to the window regulator. Tighten the front window
bolts to 9 Nm (80 lb in). 5. Install the front door outer belt sealing strip. Refer to Front Side Door
Window Belt Outer Sealing Strip Replacement (See: Windows and
Glass/Windows/Service and Repair/Front Side Door Window Belt Outer Sealing Strip
Replacement).
6. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement
(See: Front Door Panel/Service and Repair). 7. Install the front door trim panel. Refer to Front Side
Door Trim Panel Replacement (See: Front Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Motor > Component Information > Service and Repair
Front Door Window Motor: Service and Repair
Front Side Door Window Regulator Motor Replacement
Removal Procedure
Warning
Do not attempt to service the regulator motor without releasing the counterbalance spring tension.
The regulator lift arm is under tension from the counterbalance spring and can cause personal
injury if the motor is removed from the regulator.
1. Remove the front door window regulator. Refer to Front Side Door Window Regulator
Replacement (See: Front Door Window
Regulator/Service and Repair/Front Side Door Window Regulator Replacement).
2. Drill a hole (1) through the window regulator bracket and lift arm. 3. Install a nut and bolt through
the hole (1) to secure the lift arm while the motor is removed.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Motor > Component Information > Service and Repair > Page 9844
4. Remove the bolts retaining the front window regulator motor to the regulator bracket. 5. Remove
the front window regulator motor from the regulator.
Installation Procedure
1. Install the front window regulator motor to the regulator.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the front window regulator motor to the regulator bracket. Tighten the
front window regulator motor bolts to 4.5 Nm (40
lb in).
3. Remove the nut and bolt securing the lift arm to the regulator bracket. 4. Install the front window
regulator to the front door. Refer to Rear Side Door Window Regulator Replacement (See: Rear
Door/Rear Door
Window Regulator/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: >
09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling
Front Door Window Regulator: Customer Interest Body - Front Door Glass
Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: >
09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9853
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: >
09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9854
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window
Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling
Front Door Window Regulator: All Technical Service Bulletins Body - Front Door Glass
Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window
Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9860
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window
Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9861
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window
Regulator: > Page 9862
Front Door Window Regulator: By Symptom
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window
Regulator: > Page 9863
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window
Regulator: > Page 9864
Disclaimer
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window
Regulator: > Page 9865
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window
Regulator: > Page 9866
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window
Regulator: > Page 9867
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window
Regulator: > Page 9868
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window
Regulator: > Page 9869
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window
Regulator: > Page 9870
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement
Front Door Window Regulator: Service and Repair Door Window Regulator Handle Replacement
Door Window Regulator Handle Replacement
Tools Required
J 9886-01 Door Handle Clip Remover
Removal Procedure
1. Raise the window to the full up position.
2. Remove the window regulator handle from the door by inserting tool J 9886-01 between the
handle and the white plastic washer. 3. Align the J 9886-01 with the handle. 4. Push the J 9886-01
in order to disengage the clip. 5. Pull the handle from the door.
6. Remove the window regulator handle from the door. 7. Remove the bearing plate from the door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 9873
Installation Procedure
1. Ensure that the window is in the full up position. 2. Install the white plastic washer to the
regulator shaft. 3. Install the retaining clip to the handle.
4. Install the window regulator handle to the door with the handle forward at about a 50 degree
angle. 5. Push on the handle until the clip engages on the shaft.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 9874
Front Door Window Regulator: Service and Repair Front Side Door Window Regulator
Replacement
Front Side Door Window Regulator Replacement
Power window regulator (A31) shown, manual window regulator (without A31) similar.
Removal Procedure
1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front
Door Panel/Service and Repair). 2. Remove the front door water deflector. Refer to Front Side
Door Water Deflector Replacement (See: Front Door Panel/Service and Repair).
3. Remove the bolts retaining the front door window to the window regulator. 4. Remove the front
door window. Refer to Front Side Door Window Replacement (See: Front Door Window
Glass/Service and Repair).
5. Disconnect the electrical connector from the window regulator motor, if equipped with A31.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 9875
6. Loosen the bolts (1) retaining the window regulator to the inner panel at the keyhole slot
locations. 7. Remove the remaining fasteners retaining the window regulator to the inner panel. 8.
Remove the window regulator from the door by lifting the regulator up, and out of the keyhole slots,
and removing the regulator out through the
access hole.
Installation Procedure
1. Install the front door window regulator into the front door through the access hole.
2. Position the window regulator to the inner panel by sliding the regulator bolts (1) into the keyhole
slots in the inner panel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the fastener retaining the front door window regulator to the door. Tighten the front
window regulator fasteners to 9 Nm (80 lb in). 4. Connect the electrical connector to the window
regulator motor, if equipped with A31.
5. Install the front door window. Refer to Front Side Door Window Replacement (See: Front Door
Window Glass/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 9876
6. Install the bolts retaining the window to the window regulator. Tighten the front door window bolts
to 9 Nm (80 lb in). 7. Install the front door water deflector. Refer to Front Side Door Water Deflector
Replacement (See: Front Door Panel/Service and Repair). 8. Install the front door trim panel. Refer
to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle >
Rear Door Exterior Handle > System Information > Service and Repair
Rear Door Exterior Handle: Service and Repair
Rear Side Door Outside Handle Replacement
Removal Procedure
1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear
Door Panel/Service and Repair). 2. Remove the rear door speaker. Refer to Radio Rear Side Door
Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo,
and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement).
3. Remove the rear inside door handle. Refer to Rear Side Door Inside Handle Replacement (See:
Rear Door Interior Handle/Service and Repair). 4. Remove the rear door water deflector. Refer to
Rear Side Door Water Deflector Replacement (See: Rear Door Panel/Service and Repair).
5. Disconnect the rear outside door handle rod by releasing the retaining clip (1). 6. Remove the
bolts retaining the rear outside door handle to the door. 7. Remove the rear outside door handle
from the door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle >
Rear Door Exterior Handle > System Information > Service and Repair > Page 9882
1. Install the rear outside door handle to the rear door.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the rear outside door handle to the door.
Tighten the outside door handle bolts to 9 Nm (80 lb in).
3. Connect the rear outside door handle rod to the door handle using the retaining clip (1). 4. Install
the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Rear
Door Panel/Service and Repair). 5. Install the rear inside door handle. Refer to Rear Side Door
Inside Handle Replacement (See: Rear Door Interior Handle/Service and Repair). 6. Install the rear
door speaker. Refer to Radio Rear Side Door Speaker Replacement (See: Accessories and
Optional Equipment/Radio, Stereo, and
Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement).
7. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear
Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle >
Rear Door Interior Handle > System Information > Service and Repair > Rear Side Access Door Inside Handle
Replacement
Rear Door Interior Handle: Service and Repair Rear Side Access Door Inside Handle Replacement
Rear Side Access Door Inside Handle Replacement
Tools Required
J 9886-01 Door Handle Clip Remover or equivalent
Removal Procedure
1. Open the front and rear side access door. 2. Remove the spring clip retaining the rear side
access door handle by inserting J 9886-01 between the door handle, and the door, and pressing
the
spring clip off the door handle.
3. Remove the rear side access door handle from the door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle >
Rear Door Interior Handle > System Information > Service and Repair > Rear Side Access Door Inside Handle
Replacement > Page 9887
1. Install the spring clip onto the rear side access door handle.
2. Install the rear side access door handle onto the rear side access door control assembly. 3.
Press the handle in until the spring clip retaining the handle is fully seated.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle >
Rear Door Interior Handle > System Information > Service and Repair > Rear Side Access Door Inside Handle
Replacement > Page 9888
Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Replacement
Rear Side Door Inside Handle Replacement
Removal Procedure
1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear
Door Panel/Service and Repair). 2. Slide the inside door handle rearward to release the retaining
tabs (1) from the door inner panel.
3. Remove the lock cables from the inside door handle. 4. Remove the inside door handle from the
door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle >
Rear Door Interior Handle > System Information > Service and Repair > Rear Side Access Door Inside Handle
Replacement > Page 9889
1. Install the lock cables inside the door handle.
2. Insert the inside door handle retaining tabs (1) into the slots of the door inner panel. 3. Slide the
inside door handle forward until the door handle retainers are fully engaged. 4. Install the rear door
trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge >
System Information > Service and Repair > Rear Side Access Door Hinge Replacement
Rear Door Hinge: Service and Repair Rear Side Access Door Hinge Replacement
Rear Side Access Door Hinge Replacement
Removal Procedure
Note: In order to minimize door realignment, do not remove both the door hinges at the same time.
Replace the broken hinge first.
1. Open the front and rear side access door. 2. Clean the mounting surfaces of the hinges with a
clean rag, and mark the rear door hinge locations on each surface with a grease pencil, or other
suitable marker.
3. Support the rear side access door. 4. Remove the bolts retaining the hinge to the door.
5. Remove the bolts retaining the hinge to the body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge >
System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9894
6. Remove the rear side access door hinge from the body.
Installation Procedure
1. Position the rear side access door hinge to the alignment marks.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the hinge to the body and tighten to 25 Nm (18.4 lb ft).
3. Install the bolts retaining the hinge to the door and tighten to 25 Nm (18.4 lb ft). 4. Remove the
support from the rear side access door. 5. Inspect the door for proper operation and alignment.
Refer to Rear Door Adjustment (See: Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge >
System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9895
Rear Door Hinge: Service and Repair Rear Side Door Hinge Replacement - Body Side
Rear Side Door Hinge Replacement - Body Side
Removal Procedure
1. Open the door. 2. Remove the bolt retaining the rear door check link to the body. 3. Remove the
rear door wiring harness grommet from the body, and disconnect the door wiring harness
connectors. Refer to Rear Side Door Wiring
Harness Replacement (See: Service and Repair).
4. Remove the bolts (1) retaining the rear door hinge keeper straps. 5. With an assistant, lift the
rear door up off the body side hinges, and place on a clean protected surface.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge >
System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9896
6. Clean the mounting surfaces of the body side hinges with a clean rag and mark the rear door
hinge locations with a grease pencil or other suitable
marker.
7. Remove the bolts retaining the body side hinges to the body. 8. Remove the hinges from the
body.
Installation Procedure
1. Position the body side rear door hinge to the alignment marks.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the body side door hinge to the body and tighten to 25 Nm (18.4 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge >
System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9897
3. With an assistant, lower the rear door down onto the body side hinge straps. 4. Install the bolts
(1) retaining the rear door hinge keeper straps and tighten to 25 Nm (18.4 lb ft). 5. Connect the rear
door wiring harness connectors, and install the rear door wiring harness grommet to the body.
Refer to Rear Side Door Wiring
Harness Replacement (See: Service and Repair).
6. Install the bolt retaining the rear door check link to the body and tighten to 25 Nm (18.4 lb ft). 7.
Inspect the door for proper operation and alignment. Refer to Rear Door Adjustment (See:
Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge >
System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9898
Rear Door Hinge: Service and Repair Rear Side Door Hinge Replacement - Door Side
Rear Side Door Hinge Replacement - Door Side
Removal Procedure
1. Open the rear door. 2.
Remove the bolt retaining the rear door check link to the body.
3. Remove the rear door wiring harness grommet from the body and disconnect the door wiring
harness connectors. Refer to Rear Side Door Wiring
Harness Replacement (See: Service and Repair).
4. Remove the bolts (1) retaining the rear door hinge keeper straps. 5. With the aid of an assistant,
lift the rear door up off the body side hinges and place the door on a clean, protected surface.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge >
System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9899
6. Remove the bolts retaining the door side hinges to the door. 7. Remove the hinges from the
door.
Installation Procedure
1. Position the door side rear door hinge to the door.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the door side door hinge to the door and tighten to 25 Nm (18 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge >
System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9900
3. With the aid of an assistant, lower the rear door down onto the body side hinge straps. 4. Install
the bolts (1) retaining the rear door hinge keeper straps and tighten to 25 Nm (18 lb ft). 5. Connect
the rear door wiring harness connectors and install the rear door wiring harness grommet to the
body. Refer to Rear Side Door Wiring
Harness Replacement (See: Service and Repair).
6. Install the bolt retaining the rear door check link to the body and tighten to 25 Nm (18 lb ft). 7.
Inspect the door for proper operation and alignment. Refer to Rear Door Adjustment (See:
Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch >
System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door
Rear Door Latch: Service and Repair Latch Control Assembly Replacement Rear Side Access
Door
Latch Control Assembly Replacement Rear Side Access Door
Removal Procedure
1. Open the rear side access door. 2. Remove the rear side access door trim panel. Refer to Rear
Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). 3. Remove the
rear side access door latch control handle. Refer to Rear Side Access Door Inside Handle
Replacement (See: Rear Door Handle/Rear
Door Interior Handle/Service and Repair).
4. Disconnect the upper latch rod (1) from the control assembly by releasing the retaining clip (2).
5. Disconnect the lower latch rod from the control assembly by releasing the retaining clip (3). 6.
Remove the bolts retaining the latch control assembly from the rear side access door. 7. Remove
the latch control assembly from the rear side access door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch >
System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door > Page 9905
1. Install the latch control assembly to the rear side access door.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the latch control assembly to the rear side access door.
Tighten the latch control assembly bolts to 9 Nm (80 lb in).
3. Connect the lower latch rod to the latch control assembly using the retaining clip (3). 4. Connect
the upper latch rod (1) to the control assembly using the retaining clip (2). 5. Install the rear side
access door latch control handle. Refer to Rear Side Access Door Inside Handle Replacement
(See: Rear Door Handle/Rear
Door Interior Handle/Service and Repair).
6. Install the rear side access door trim panel. Refer to Rear Side Door Trim Panel Replacement
(See: Rear Door Panel/Service and Repair). 7. Close the rear side access door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch >
System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door > Page 9906
Rear Door Latch: Service and Repair Rear Side Access Door Latch Replacement - Lower
Rear Side Access Door Latch Replacement - Lower
Removal Procedure
1. Open the rear side access door. 2. Remove the rear side access door trim panel. Refer to Rear
Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair).
3. Disconnect the lower latch rod (1) from the latch by releasing the retaining clip (2).
4. Remove the bolts retaining the lower latch to the rear side access door. 5. Remove the nut
retaining the lower latch to the rear side access door. 6. Remove the lower latch from the rear side
access door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch >
System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door > Page 9907
Installation Procedure
1. Install the lower latch to the rear side access door.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the lower latch to the rear side access door.
Tighten the rear side access door lower latch bolts to 9 Nm (80 lb in).
3. Install the nut retaining the lower latch to the rear side access door.
Tighten the rear side access door lower latch nut to 9 Nm (80 lb in).
4. Connect the lower latch rod (1) to the latch using the retaining clip (2). 5. Install the rear side
access door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door
Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch >
System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door > Page 9908
6. Close the rear side access door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch >
System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door > Page 9909
Rear Door Latch: Service and Repair Rear Side Access Door Latch Replacement - Upper
Rear Side Access Door Latch Replacement - Upper
Removal Procedure
1. Open the rear side access door. 2. Remove the rear side access door trim panel. Refer to Rear
Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair).
3. Disconnect the upper latch rod from the latch by releasing the retaining clip. 4. Remove the bolts
(1, 2) retaining the upper latch to the rear side access door. 5. Remove the upper latch from the
rear side access door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch >
System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door > Page 9910
1. Install the upper latch to the rear side access door.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Loosely install the lower bolts (2) retaining the upper latch to the rear side access door.
Tighten the lower rear side access door upper latch bolts (2) until the latch bracket is flush to the
door panel.
3. Connect the upper latch rod to the latch using the retaining clips. 4. Close the rear side access
door to self align the upper latch. 5. Finish tightening the lower rear side access door upper latch
bolts.
Tighten the upper latch bolts to 9 Nm (80 lb in).
6. Open the rear side access door. 7. Install the upper rear side access door upper latch bolt (1).
Tighten the upper latch bolt to 9 Nm (80 lb in).
8. Install the rear side access door trim panel. Refer to Rear Side Door Trim Panel Replacement
(See: Rear Door Panel/Service and Repair). 9. Close the rear side access door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter >
System Information > Service and Repair > Door Check Link Replacement Rear Side Access
Rear Door Limiter: Service and Repair Door Check Link Replacement Rear Side Access
Door Check Link Replacement Rear Side Access
Removal Procedure
1. Remove the rear side access door trim panel. Refer to Rear Side Door Trim Panel Replacement
(See: Rear Door Panel/Service and Repair).
2. Remove the bolt retaining the rear side access door check link to the body.
3. Remove the nuts retaining the rear side access door check link to the door. 4. Remove the rear
side access door check link (1) from the door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter >
System Information > Service and Repair > Door Check Link Replacement Rear Side Access > Page 9915
1. Install the rear side door check link to the door, ensuring the alignment mark (1) faces upward.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the nuts retaining the rear side door check link to the door and tighten to 9 Nm (80 lb in).
3. Install the bolt retaining the rear side access check link to the body and tighten to 25 Nm (18.4 lb
ft). 4. Install the rear side access door trim panel. Refer to Rear Side Door Trim Panel Replacement
(See: Rear Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter >
System Information > Service and Repair > Door Check Link Replacement Rear Side Access > Page 9916
Rear Door Limiter: Service and Repair Rear Side Door Check Link Replacement
Rear Side Door Check Link Replacement
Removal Procedure
1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear
Door Panel/Service and Repair). 2. Remove the rear inside door handle. Refer to Rear Side Door
Inside Handle Replacement (See: Rear Door Handle/Rear Door Interior
Handle/Service and Repair).
3. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement
(See: Rear Door Panel/Service and Repair).
4. Remove the bolt retaining the rear door check link to the body.
5. Remove the nuts retaining the rear door check link to the door. 6. Remove the rear door check
link from the door (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter >
System Information > Service and Repair > Door Check Link Replacement Rear Side Access > Page 9917
Installation Procedure
1. Install the rear door check link to the door, ensuring the alignment mark (1) faces upward.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the nuts retaining the rear door check link to the door and tighten to 9 Nm (80 lb in).
3. Install the bolt retaining the check link to the body and tighten to 25 Nm (18.4 lb ft). 4. Install the
rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Rear Door
Panel/Service and Repair). 5. Install the rear door inside handle. Refer to Rear Side Door Inside
Handle Replacement (See: Rear Door Handle/Rear Door Interior
Handle/Service and Repair).
6. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear
Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel >
System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement
Rear Door Panel: Service and Repair Rear Side Access Door Trim Panel Replacement
Rear Side Access Door Trim Panel Replacement
Removal Procedure
1. Remove the front seat belt assembly. Refer to Front Seat Belt Replacement (Crew Cab) (See:
Restraint Systems/Seat Belt Systems/Seat
Belt/Service and Repair/Front Seat Belt Replacement (Crew Cab))Front Seat Belt Replacement
(Regular and Extended Cab) (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and
Repair/Front Seat Belt Replacement (Regular and Extended Cab)).
2. Remove the 2 retaining screws from the armrest. 3. Gently pull the lower side access door trim
panel away from the door. 4. Remove any fasteners from the door and reinsert them in the lower
side access door trim panel before installing the panel on the door.
5. Grasp the upper side access door trim panel and pull panel away from the door to release the
fasteners.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel >
System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9922
6. Remove any fasteners from the door and reinsert them in the upper side access door trim panel
before installing the panel on the door.
Installation Procedure
1. Install the upper side access door trim panel to the door, ensuring that all the retaining tabs are
fully seated. 2. Install the lower side access door trim panel to the door, ensuring that all the
retaining tabs are fully seated.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the 2 retaining screws in the armrest. Tighten the rear side access door armrest screws to
2 Nm (18 lb in). 4. Install the front seat belt assembly. Refer to Front Seat Belt Replacement (Crew
Cab) (See: Restraint Systems/Seat Belt Systems/Seat
Belt/Service and Repair/Front Seat Belt Replacement (Crew Cab))Front Seat Belt Replacement
(Regular and Extended Cab) (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and
Repair/Front Seat Belt Replacement (Regular and Extended Cab)).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel >
System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9923
Rear Door Panel: Service and Repair Rear Side Door Trim Panel Replacement
Rear Side Door Trim Panel Replacement
Special Tools
J 9886-01 Door Handle Clip Remover
Removal Procedure
1. Remove the window regulator handle from the door by inserting tool J 9886-01 between the
handle and the white plastic washer to remove the
retaining clip, if the vehicle is equipped with manual windows.
2. Remove the retaining screw from the door handle bezel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel >
System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9924
3. Remove the 2 retaining screws from the armrest.
4. Disconnect the electrical harness from the power window switch, if equipped.
5. Gently pull the door panel away from the door. 6. Remove any fasteners from the door and
reinsert them in the door panel before installing the panel on the door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel >
System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9925
1. Install the trim panel to the door, ensuring that all the retaining tabs are fully seated.
2. Connect the electrical harness to the power window switch, if equipped.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel >
System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9926
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the 2 retaining screws in the switch plate. Tighten the rear door switch plate screws to 2
Nm (18 lb in).
4. Install the retaining screw in the door handle bezel. Tighten the rear door handle bezel screws to
2 Nm (18 lb in). 5. Install the window regulator handle from the door and insert the clip between the
handle and the white plastic washer, if the vehicle is equipped
with manual windows.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel >
System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9927
Rear Door Panel: Service and Repair Rear Side Door Water Deflector Replacement
Rear Side Door Water Deflector Replacement
Removal Procedure
1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: ). 2.
Remove the rear door inside handle. Refer to Rear Side Door Inside Handle Replacement (See:
Rear Door Handle/Rear Door Interior
Handle/Service and Repair).
3. Remove the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See:
Accessories and Optional Equipment/Radio, Stereo,
and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement).
4. Remove the rear door water deflector from the rear door inner panel. 5. Pull the electrical
connectors through the slit in the water deflector.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel >
System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9928
1. Align the rear door water deflector to the rear door inner panel. Secure the water deflector at the
corners. 2. Pull the rear door electrical connectors through the slit in the water deflector. 3. Install
the rear door water deflector. Start pressing the adhesive pattern at the bottom center and working
outward and upward in order to prevent
puckering.
4. Install the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See:
Accessories and Optional Equipment/Radio, Stereo, and
Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement).
5. Install the rear door inside handle. Refer to Rear Side Door Inside Handle Replacement (See:
Rear Door Handle/Rear Door Interior
Handle/Service and Repair).
6. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker >
System Information > Adjustments
Rear Door Striker: Adjustments
Door Lock Striker Adjustment
1. Ensure that the door is properly aligned within the door opening before proceeding with the
striker adjustment. Refer to Front Side Door
Adjustment (See: Front Door/Adjustments) and Rear Door Adjustment (See: Adjustments).
2. Close the door onto the striker and note if the door drags on the striker causing the door to move
upward or downward upon contact with the
striker. Also note closing effort to fully engage the latch.
3. Mark the position of the door striker with a grease pencil. 4. Loosen the screws retaining the
door striker to the body. 5. Move the striker to eliminate drag on the striker and door latch and to
achieve the proper door position within the door opening. Start with the
up/down position, then position the striker to achieve proper alignment to the door opening. Set the
in/out adjustment for the proper door seal engagement ensuring that the door closing efforts are
correct.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Tighten the screws retaining the door striker to the body.
Tighten the door striker screws to 25 Nm (18 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker >
System Information > Service and Repair > Rear Side Door Latch Striker Replacement - Lower
Rear Door Striker: Service and Repair Rear Side Door Latch Striker Replacement - Lower
Rear Side Door Latch Striker Replacement - Lower
Removal Procedure
1. Open the rear side access door. 2. Remove the bolts retaining the lower side access door striker
to the body. 3. Remove the lower side access door striker from the body.
Installation Procedure
1. Install the lower side access door striker to the body.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker >
System Information > Service and Repair > Rear Side Door Latch Striker Replacement - Lower > Page 9934
2. Install the bolts retaining the lower side access door striker to the body.
Tighten the lower side access door striker bolts to 25 Nm (18 lb ft).
3. Close the rear side access door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker >
System Information > Service and Repair > Rear Side Door Latch Striker Replacement - Lower > Page 9935
Rear Door Striker: Service and Repair Rear Side Door Latch Striker Replacement - Upper
Rear Side Door Latch Striker Replacement - Upper
Removal Procedure
1. Open the rear side access door. 2. Remove the rear side access upper door striker trim cover.
Refer to Rear Side Door Latch Striker Cover Replacement (Extended Cab) (See:
Interior Moulding / Trim/Trim Panel/Service and Repair).
3. Remove the bolts retaining the upper side access door striker to the body. 4. Remove the upper
side access door striker from the body.
Installation Procedure
1. Install the upper side access door striker to the body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker >
System Information > Service and Repair > Rear Side Door Latch Striker Replacement - Lower > Page 9936
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the upper side access door striker to the body.
Tighten the upper side access door striker bolts to 25 Nm (18 lb ft).
3. Install the rear side access upper door striker trim cover. Refer to Rear Side Door Latch Striker
Cover Replacement (Extended Cab) (See: Interior
Moulding / Trim/Trim Panel/Service and Repair).
4. Close the rear side access door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement
Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement
Rear Door Opening Weatherstrip Replacement
Removal Procedure
1. Open the rear door. 2. Remove the lower center pillar trim panel. Refer to Center Pillar Lower
Trim Panel Replacement (See: Interior Moulding / Trim/Trim
Panel/Service and Repair).
3. Remove the rear door opening weatherstrip (2) from the door opening pinchweld flange (1). 4.
Remove the rear door opening weatherstrip from the vehicle.
Installation Procedure
1. Position the rear door opening weatherstrip to the pinchweld flange.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9941
2. Starting at the upper rear corner, press the rear door opening weatherstrip (2) onto the
pinchweld flange (1) until it is fully seated. 3. Install the lower center pillar trim panel. Refer to
Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim
Panel/Service and Repair).
4. Pull the cord (3) on the rear door opening weatherstrip ensuring the weatherstrip lip overlaps the
interior trim panels and headliner. 5. Close the rear door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9942
Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Replacement
Rear Door Weatherstrip Replacement
Tools Required
J 38778 Door Trim Pad Clip Remover or Equivalent
Removal Procedure
1. Open the rear door. 2. Remove the weatherstrip from around the door by inserting J 38778 , or
equivalent, under the weatherstrip and releasing the integral retainers (2)
from the door frame.
3. Remove the weatherstrip from the rear door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9943
1. Position the weatherstrip to the rear door. 2. Install the weatherstrip around the rear door frame
using the integral retainers (2). 3. Close the rear door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9944
Rear Door Weatherstrip: Service and Repair Rear Side Access Door Auxiliary Weatherstrip
Replacement
Rear Side Access Door Auxiliary Weatherstrip Replacement
Removal Procedure
1. Open the front and side access doors. 2. Remove the rear door outer auxiliary weatherstrip by
pulling the weatherstrip from the rear door pinchweld flange.
Installation Procedure
1. Install the rear door auxiliary weatherstrip to the rear door pinchweld flange, by pressing the
weatherstrip into place until it is fully seated. 2. Close the front and side doors.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9945
Rear Door Weatherstrip: Service and Repair Rear Side Door Wedge Replacement - Body Side
Rear Side Door Wedge Replacement - Body Side
Removal Procedure
1. Open the rear side access door. 2. Apply tape to the area around the wedge to protect the paint.
3. Heat the wedge (1) using a heat gun 152 mm (6 in) from the surface. 4. Apply the heat using a
circular motion for about 30 seconds. 5. Remove the wedge from the body using a plastic,
flat-bladed tool. 6. Remove all adhesive from the body using 3M Scotch Brite molding adhesive
remover disk 3M P/N 07201, or equivalent. 7. Clean the body surface using varnish makers and
painters (VMP) naptha.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9946
1. Warm the body surface with a heat gun 152 mm (6 in) from the surface to a minimum of 21°C
(70°F). 2. Remove the backing from the wedge (1). 3. Align the tabs on the wedge to the holes in
the body. 4. Press the wedge to the body surface. 5. Inspect the wedge for proper adhesion. 6.
Remove the tape from the area around the wedge. 7. Close the rear side access door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9947
Rear Door Weatherstrip: Service and Repair
Rear Door Opening Weatherstrip Replacement
Rear Door Opening Weatherstrip Replacement
Removal Procedure
1. Open the rear door. 2. Remove the lower center pillar trim panel. Refer to Center Pillar Lower
Trim Panel Replacement (See: Interior Moulding / Trim/Trim
Panel/Service and Repair).
3. Remove the rear door opening weatherstrip (2) from the door opening pinchweld flange (1). 4.
Remove the rear door opening weatherstrip from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9948
1. Position the rear door opening weatherstrip to the pinchweld flange. 2. Starting at the upper rear
corner, press the rear door opening weatherstrip (2) onto the pinchweld flange (1) until it is fully
seated. 3. Install the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel
Replacement (See: Interior Moulding / Trim/Trim
Panel/Service and Repair).
4. Pull the cord (3) on the rear door opening weatherstrip ensuring the weatherstrip lip overlaps the
interior trim panels and headliner. 5. Close the rear door.
Rear Door Weatherstrip Replacement
Rear Door Weatherstrip Replacement
Tools Required
J 38778 Door Trim Pad Clip Remover or Equivalent
Removal Procedure
1. Open the rear door. 2. Remove the weatherstrip from around the door by inserting J 38778 , or
equivalent, under the weatherstrip and releasing the integral retainers (2)
from the door frame.
3. Remove the weatherstrip from the rear door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9949
1. Position the weatherstrip to the rear door. 2. Install the weatherstrip around the rear door frame
using the integral retainers (2). 3. Close the rear door.
Rear Side Access Door Auxiliary Weatherstrip Replacement
Rear Side Access Door Auxiliary Weatherstrip Replacement
Removal Procedure
1. Open the front and side access doors. 2. Remove the rear door outer auxiliary weatherstrip by
pulling the weatherstrip from the rear door pinchweld flange.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9950
1. Install the rear door auxiliary weatherstrip to the rear door pinchweld flange, by pressing the
weatherstrip into place until it is fully seated. 2. Close the front and side doors.
Rear Side Door Wedge Replacement - Body Side
Rear Side Door Wedge Replacement - Body Side
Removal Procedure
1. Open the rear side access door. 2. Apply tape to the area around the wedge to protect the paint.
3. Heat the wedge (1) using a heat gun 152 mm (6 in) from the surface. 4. Apply the heat using a
circular motion for about 30 seconds. 5. Remove the wedge from the body using a plastic,
flat-bladed tool. 6. Remove all adhesive from the body using 3M Scotch Brite molding adhesive
remover disk 3M P/N 07201, or equivalent. 7. Clean the body surface using varnish makers and
painters (VMP) naptha.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9951
Installation Procedure
1. Warm the body surface with a heat gun 152 mm (6 in) from the surface to a minimum of 21°C
(70°F). 2. Remove the backing from the wedge (1). 3. Align the tabs on the wedge to the holes in
the body. 4. Press the wedge to the body surface. 5. Inspect the wedge for proper adhesion. 6.
Remove the tape from the area around the wedge. 7. Close the rear side access door.
Rear Side Door Wedge Replacement - Door Side
Rear Side Door Wedge Replacement - Door Side
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9952
1. Open the rear side access door. 2. Remove the wedge from the side access door by squeezing
the retainer clip on the wedge and rotating the wedge downward.
Installation Procedure
1. Install the wedge to the side access door by inserting the tabs into the slots on the door and
rotating the wedge up until the retaining clip is fully
seated.
2. Close the rear side access door.
Weatherstrip Replacement Rear Side Access Door
Weatherstrip Replacement Rear Side Access Door
Tools Required
J 38778 Door Trim Pad Clip Remover or Equivalent
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9953
Removal Procedure
1. Open the front and rear side access doors. 2. Remove the upper molded detail from the front of
the side access door, by inserting J 38778 under the weatherstrip mold and releasing the
integral retaining pins (3) on the mold to the door.
3. Remove the lower molded detail from the front of the side access door, by inserting J 38778
under the weatherstrip mold and releasing the
integral retaining pins (1) on the mold to the door.
4. Remove the weatherstrip from around the door, by inserting J 38778 under the weatherstrip on
releasing the integral pins from the door. 5. Remove the weatherstrip from the side access door.
Installation Procedure
1. Position the weatherstrip to the rear side access door. 2. Install the upper molded detail to the
front of the rear side access door using the integral retaining pins (1). 3. Install the lower molded
detail to the front of the rear side access door using the integral retaining pins (1). 4. Install the
weatherstrip around the rear door frame using the integral retainers.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9954
5. Close the front and rear side access doors.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window
Glass > System Information > Service and Repair
Rear Door Window Glass: Service and Repair
Rear Side Door Window Replacement
Removal Procedure
1. Position the rear door window in the full up position. 2. Remove the rear door trim panel. Refer to
Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). 3. Remove
the rear inside door handle. Refer to Rear Side Door Inside Handle Replacement (See: Rear Door
Handle/Rear Door Interior
Handle/Service and Repair).
4. Remove the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See:
Accessories and Optional Equipment/Radio, Stereo,
and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement).
5. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement
(See: Rear Door Panel/Service and Repair). 6. Remove the rear window run channel. Refer to
Rear Side Door Window Channel Replacement (See: Windows and Glass/Windows/Service and
Repair/Rear Side Door Window Channel Replacement).
7. Lower the rear door window in the full down position.
8. Remove the bolts retaining the rear door window to the window regulator. 9. Lift the rear window
off the regulator. Carefully lower the window down into the door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window
Glass > System Information > Service and Repair > Page 9958
10. Remove the window from the door by sliding the window out between the inner panel (1) and
the upper window channel (2).
Installation Procedure
1. Install the rear door window to the rear door by inserting the front edge of the window into the
window channel (3), and sliding the rear of the
window down between the upper window channel (2) and the inner panel (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window
Glass > System Information > Service and Repair > Page 9959
2. Position the rear door window onto the window regulator.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the bolts retaining the rear door window to the window regulator. Tighten the rear window
bolts to 9 Nm (80 lb in). 4. Raise the window to the full up position. 5. Install the rear door window
run channel. Refer to Rear Side Door Window Channel Replacement (See: Windows and
Glass/Windows/Service
and Repair/Rear Side Door Window Channel Replacement).
6. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See:
Rear Door Panel/Service and Repair). 7. Install the rear door speaker. Refer to Radio Rear Side
Door Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and
Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement).
8. Install the rear door inside handle. Refer to Rear Side Door Inside Handle Replacement (See:
Rear Door Handle/Rear Door Interior
Handle/Service and Repair).
9. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear
Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window
Motor > Component Information > Service and Repair
Rear Door Window Motor: Service and Repair
Rear Side Door Window Regulator Motor Replacement
Removal Procedure
1. Remove the rear door window regulator. Refer to Rear Side Door Window Regulator
Replacement (See: Rear Door Window Regulator/Service
and Repair).
2. Remove the bolts retaining the rear window regulator motor to the regulator bracket. 3. Remove
the rear window regulator motor from the regulator.
Installation Procedure
1. Install the rear window regulator motor to the regulator.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window
Motor > Component Information > Service and Repair > Page 9963
2. Install the bolts retaining the rear window regulator motor to the regulator bracket. Tighten the
rear window regulator motor bolts to 4.5 Nm (40 lb
in).
3. Install the rear door window regulator. Refer to Rear Side Door Window Regulator Replacement
(See: Rear Door Window Regulator/Service
and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window
Regulator > System Information > Service and Repair
Rear Door Window Regulator: Service and Repair
Rear Side Door Window Regulator Replacement
Manual window regulator (without A31) shown, power regulator (A31) similar.
Removal Procedure
1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear
Door Panel/Service and Repair). 2. Remove the rear inside door handle. Refer to Rear Side Door
Inside Handle Replacement (See: Rear Door Handle/Rear Door Interior
Handle/Service and Repair).
3. Remove the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See:
Accessories and Optional Equipment/Radio, Stereo,
and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement).
4. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement
(See: Rear Door Panel/Service and Repair).
5. Remove the bolts retaining the rear window to the window regulator. 6. Raise and support the
rear door window.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window
Regulator > System Information > Service and Repair > Page 9967
7. Disconnect the electrical connector from the window regulator motor, if equipped with A31. 8.
Loosen the bolts retaining the window regulator (1) to the inner door at the keyhole slot (2)
locations. 9. Remove the bolts retaining the window regulator to the inner panel.
10. Remove the window regulator (1) by lifting the regulator up, and out of the keyhole slots (2) in
the inner panel, and removing the regulator out
through the access hole.
Installation Procedure
1. Install the rear door window regulator (1) into the rear door through the access hole. 2. Position
the rear door window regulator to the inner panel by inserting the regulator bolts to the keyhole
slots (2) on the inner panel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the bolts retaining the rear door window regulator to the inner panel. Tighten the rear
window regulator bolts to 9 Nm (80 lb in). 4. Connect the electrical connector to the window
regulator motor, if equipped with A31.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window
Regulator > System Information > Service and Repair > Page 9968
5. Remove the window support and lower the window onto the window regulator carrier plate. 6.
Install the bolts retaining the window to the window regulator. Tighten the rear window bolts to 9
Nm (80 lb in). 7. Install the rear door water deflector. Refer to Rear Side Door Water Deflector
Replacement (See: Rear Door Panel/Service and Repair). 8. Install the rear door speaker. Refer to
Radio Rear Side Door Speaker Replacement (See: Accessories and Optional Equipment/Radio,
Stereo, and
Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement).
9. Install the rear door inside handle. Refer to Rear Side Door Inside Handle Replacement (See:
Rear Door Handle/Rear Door Interior
Handle/Service and Repair).
10. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear
Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service
and Repair
Fuel Door: Service and Repair
Fuel Tank Filler Door Replacement
Removal Procedure
1. Remove the screws (2) that retain the fuel filler door to the body. 2. Remove the fuel filler door
(1) from the body.
Installation Procedure
1. Position the fuel filler door (1) to the body.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the fuel filler door retaining screws (2) to the body and tighten to 5 Nm (44 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information
> Service and Repair
Hood Hinge: Service and Repair
Hood Hinge Replacement
Removal Procedure
1. Remove the hood. Refer to Hood Replacement (See: Service and Repair). 2. Remove the front
fender. Refer to Front Fender Replacement (See: Fender/Front Fender/Service and Repair).
3. Using a grease pencil or other suitable marking device, mark the location of the hinges to the
body. 4. Remove the bolts that retain the hinges. 5. Remove the hinges from the body.
Installation Procedure
1. Position the hinges to the body as previously marked.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information
> Service and Repair > Page 9976
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts that retain the hinges to the body and tighten to 25 Nm (18 lb ft). 3. Install the
front fender. Refer to Front Fender Replacement (See: Fender/Front Fender/Service and Repair).
4. Install the hood. Refer to Hood Replacement (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information
> Adjustments
Hood Latch: Adjustments
Hood Latch Adjustment
Inspection Procedure
1. Release the primary hood latch in order to inspect the operation of the pop-up spring. 2. Attempt
to raise the hood while the hood is in the pop-up position.
* The hood should raise without the hood striker binding against the latch.
* The secondary latch should engage in order to prevent the hood from being raised.
Adjustment Procedure
1. Loosen the bolts (1, 2) retaining the hood latch to the radiator support and the support bracket.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Move the hood latch from side to side until the striker enters the center of the latch assembly.
Tighten the bolts (1, 2) to 10 Nm (89 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information
> Adjustments > Page 9980
Hood Latch: Service and Repair
Hood Primary and Secondary Latch Replacement
Removal Procedure
1. Remove the grille. Refer to Grille Replacement (See: Grille/Service and Repair).
2. Using a grease pencil or other suitable marking device, mark the location of the latch on the
radiator support. 3. Remove the hood latch support (3). 4. Remove the bolts that retain the latch to
the radiator support (1).
5. Disconnect the hood latch cable from the latch. 6. Remove the latch from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information
> Adjustments > Page 9981
1. Connect the hood latch cable to the latch.
2. Position the latch to the previously marked location on the radiator support.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the bolts which retain the latch to the radiator support and tighten to 10 Nm (89 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information
> Adjustments > Page 9982
4. Install the hood latch support (3). 5. Install the bolts which retain the latch support and tighten to
10 Nm (89 lb in). 6. Inspect the latch for proper operation before closing the hood. 7. Inspect the
alignment of the latch to the hood striker. Adjust the latch, if necessary. Refer to Hood Latch
Adjustment (See: Adjustments). 8. Install the grille. Refer to Grille Replacement (See: Grille/Service
and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable >
Component Information > Service and Repair
Hood Latch Release Cable: Service and Repair
Hood Primary Latch Release Cable Replacement
Removal Procedure
1. Remove the grille. Refer to Grille Replacement (See: Grille/Service and Repair). 2. Remove the
hood latch. Refer to Hood Primary and Secondary Latch Replacement (See: Hood Latch/Service
and Repair).
3. Release the hood latch release cable from the hood latch assembly. 4. Attach a length of
mechanic's wire to the exterior end of the cable, and note the routing of the cable for later
installation. 5. Release the retainers securing the cable to the inner fender and the radiator support.
6. Push the cable grommet (1) through the cowl panel and into the interior of the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable >
Component Information > Service and Repair > Page 9986
7. Remove the bolts attaching the hood release handle to the knee bolster. 8. Remove the cable
from the release handle. 9. Pull the cable the rest of the way through the cowl panel and out from
behind the sound insulation.
10. Detach the mechanic's wire from the cable, leaving the wire in position for aid in installation of
the cable. 11. Remove the cable from the vehicle.
Installation Procedure
1. Attach the mechanic's wire to the exterior end of the cable. 2. Using the mechanic's wire as an
aid, guide the cable underneath the sound insulation and pass the exterior portion of the cable
through the cowl
panel.
3. Install the cable to the release handle. 4. Seat the cable grommet (1) to the cowl panel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable >
Component Information > Service and Repair > Page 9987
5. Install the release handle to the knee bolster.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
6. Install the bolts that retain the release handle to the knee bolster and tighten to 1 Nm (9 lb in).
7. Route the cable as previously noted. 8. Attach the cable to the retainers on the inner fender. 9.
Install the cable to the hood latch assembly.
10. Install the hood latch. Refer to Hood Primary and Secondary Latch Replacement (See: Hood
Latch/Service and Repair). 11. Install the grille. Refer to Grille Replacement (See: Grille/Service
and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component
Information > Service and Repair
Hood Shock / Support: Service and Repair
Hood Hold-Open Rod Replacement
Removal Procedure
1. Raise the hood. Support the hood with something other than the prop rod. 2. Remove the bolt
retaining the prop rod to the radiator support. 3. Remove the prop rod.
Installation Procedure
1. Install the prop rod to the radiator support.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component
Information > Service and Repair > Page 9991
2. Install the prop rod bolt and tighten to 10 Nm (89 lb in). 3. Remove the temporary hood support.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component
Information > Service and Repair > Hood Front Seal Replacement
Hood Weatherstrip: Service and Repair Hood Front Seal Replacement
Hood Front Seal Replacement
Removal Procedure
1. Open the hood.
2. Remove the front hood seal by pulling downward on the seal, starting from one end.
Installation Procedure
1. Open the hood.
2. Install the front hood seal by pressing the retainers into the hood openings.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component
Information > Service and Repair > Hood Front Seal Replacement > Page 9996
3. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component
Information > Service and Repair > Hood Front Seal Replacement > Page 9997
Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement
Hood Rear Seal Replacement
Removal Procedure
1. Open the hood. 2. Grasp the rear hood seal at each retainer and lift upwards to remove. 3.
Remove the seal from the upper cowl panel.
Installation Procedure
1. Position the seal to the upper cowl panel. 2. Insert each retainer into the holes in the body. 3.
Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Technical Service Bulletins > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION
Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION
NOTIFICATION
TECHNICAL
Bulletin No.: 06-08-111-004B
Date: September 25, 2009
Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems
Including Chevy Bowtie (Bulletin Cancelled)
Models:
2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2009 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number
06-08-111-004A (Section 08 - Body & Accessories).
This bulletin is being cancelled. The information is no longer applicable.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement
Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement
Endgate Emblem/Nameplate Replacement (GMC Canyon SL)
Endgate Emblem/Nameplate Replacement (Colorado LT)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10005
Endgate Emblem/Nameplate Replacement (Colorado LS)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10006
Endgate Emblem/Nameplate Replacement (Colorado)
Endgate Emblem/Nameplate Replacement (GMC SLE)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10007
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10008
Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (ISUZU i-290)
Endgate Emblem/Nameplate Replacement (ISUZU i-290)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10009
Body Emblem: Service and Repair Front Side Door Emblem/Nameplate Replacement (ISUZU
i-290)
Front Side Door Emblem/Nameplate Replacement (ISUZU i-290)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10010
Body Emblem: Service and Repair Front Side Door Emblem/Nameplate Replacement (GME)
Front Side Door Emblem/Nameplate Replacement (GME)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10011
Body Emblem: Service and Repair
Endgate Emblem/Nameplate Replacement
Endgate Emblem/Nameplate Replacement (GMC Canyon SL)
Endgate Emblem/Nameplate Replacement (Colorado LT)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10012
Endgate Emblem/Nameplate Replacement (Colorado LS)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10013
Endgate Emblem/Nameplate Replacement (Colorado)
Endgate Emblem/Nameplate Replacement (GMC SLE)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10014
Endgate Emblem/Nameplate Replacement (ISUZU i-290)
Endgate Emblem/Nameplate Replacement (ISUZU i-290)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10015
Front Side Door Emblem/Nameplate Replacement (ISUZU i-290)
Front Side Door Emblem/Nameplate Replacement (ISUZU i-290)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10016
Front Side Door Emblem/Nameplate Replacement (GME)
Front Side Door Emblem/Nameplate Replacement (GME)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10017
Front Side Door Emblem/Nameplate Replacement
Front Side Door Emblem/Nameplate Replacement (Colorado)
Special Tools
J 25070 Heat Gun
Removal Procedure
Note: Use the tape for protection and alignment marks for alignment of the new emblem.
1. Apply tape to the area around the door emblem. 2. Heat the emblem/nameplate, using a J 25070
, 152 mm (6 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds.
Caution: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name
plate.
4. Remove the emblem/nameplate from the door surface using a plastic, flat-bladed tool.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10018
5. Remove all adhesive from the door panel surface and the back of the emblem/nameplate using
3M(TM) scotch brite molding adhesive remover
disk 3M(TM) P/N 07501 or equivalent.
6. Clean the door surface using varnish makers and painters (VMP) naphtha.
Installation Procedure
1. If the location of the emblem/nameplate has not been marked, apply tape and use the following
dimensions:
* Dimension (a) is 166 mm (6.54 in) from the bottom of the door to the emblem/nameplate.
* Dimension (b) is 117.4 mm (4.62 in) from the front of the door to the front of the
emblem/nameplate.
2. Warm the door surface with a J 25070 , 152 mm (6 in) from the surface to a minimum of 21°C
(70°F).
Note: Do not touch the adhesive backing of the emblem/nameplate.
3. Remove the backing from the front end of the emblem/nameplate. 4. Press the
emblem/nameplate to the door panel surface while continuing to remove the backing. 5. Hand roll
the emblem/nameplate to the door panel to ensure proper adhesion. 6. Inspect the
emblem/nameplate for bonding. 7. Remove the tape from the area around the door emblem.
Pickup Box Side Emblem and Side Rear Nameplate Replacement
Pickup Box Side Emblem and Side Rear Nameplate Replacement (Colorado)
Special Tools
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10019
J 25070 Heat Gun
Removal Procedure
Note: Use the tape for protection and alignment marks for alignment of the new decal.
1. Apply tape to the area around the decal. 2. Heat the decal, using a J 25070 , 152 mm (6 in) from
the surface. 3. Apply the heat using a circular motion for about 30 seconds.
Caution: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name
plate.
4. Remove the decal from the painted surface using a plastic, flat-bladed tool.
5. Remove all adhesive from the painted surface using 3M(TM) Scotch Brite molding adhesive
remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the painted surface using varnish makers
and painters (VMP) naptha. 7. Remove the tail lamp. Refer to Tail Lamp Replacement (See:
Lighting and Horns/Tail Lamp/Service and Repair).
Installation Procedure
1. If the location of the decal has not been marked, apply tape and use the following dimensions:
* Dimension (a) is 207.1 mm (8.15 in) from the top edge of the pickup box to the highest point on
the decal.
* Dimension (b) is 71.8 mm (2.83 in) from the rear of the decal to the rear of the sheet metal in the
tail lamp opening.
2. Warm the door surface with a J 25070 , 152 mm (6 in) from the surface to a minimum of 21°C
(70°F).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10020
Note: Do not touch the adhesive backing on the decal.
3. Remove the backing from the front end of the decal. 4. Press the decal to the painted surface
while continuing to remove the backing. 5. Hand roll the decal to the panel to ensure proper
adhesion. 6. Inspect the decal for bonding. 7. Remove the tape from the area around the decal. 8.
Install the tail lamp. Refer to Tail Lamp Replacement (See: Lighting and Horns/Tail Lamp/Service
and Repair).
Radiator Grille Emblem/Nameplate Replacement
Radiator Grille Emblem/Nameplate Replacement
Removal Procedure
1. Remove the grille. Refer to Grille Replacement (See: Grille/Service and Repair). 2. Place the
grille on a clean, prepared surface.
3. Remove the emblem retaining nuts. 4. Remove the emblem from the grille.
Installation Procedure
1. Install the emblem to the grille.
Notice: Refer to Fastener Notice .
2. Install the nuts that retain the emblem to the grille.
Tighten the nuts to 3 Nm (27 lb in).
3. Install the grille. Refer to Grille Replacement (See: Grille/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information >
Service and Repair
Cowl Moulding / Trim: Service and Repair
Air Inlet Grille Panel Replacement
Removal Procedure
1. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper
and Washer Systems/Wiper Arm/Service and
Repair).
2. Remove the air inlet grill panel push-pin retainers. 3. Disconnect the washer hose. 4. Remove
the air inlet grille panel from the vehicle.
Installation Procedure
1. Position the air inlet grille panel to the vehicle. 2. Connect the washer hose.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information >
Service and Repair > Page 10024
3. Install the push-pin retainers. 4. Install the windshield wiper arms. Refer to Windshield Wiper
Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component
Information > Service and Repair
Lower Side Moulding / Trim: Service and Repair
Body Side Lower Rear Molding Replacement (B84)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component
Information > Service and Repair
Upper Side Moulding / Trim: Service and Repair
Body Side Molding Replacement
Tools Required
J 25070 Heat Gun
Removal Procedure
1. Remove the molding from the vehicle using the following procedure:
1. Heat the door side molding using a J 25070 . Hold the heat gun approximately 152 mm (6 in)
from surface.
Apply heat using a circular motion for about 30 seconds. Important: Be careful not to scratch or
chip the paint.
2. Peel the door side molding from the panel surface using a flat-bladed tool.
2. Remove all adhesive from the body panel and the back of the door side molding using a 3M(TM)
scotch brite molding adhesive remover disk
3M(TM) P/N 07501 or equivalent.
3. Clean the body panel using varnish makers and painters (VMP) naphtha.
Installation Procedure
1. Ensure the painted body surface in the tape contact area is clean and dry. 2. Warm the body
panel with a heat lamp or heat gun, if necessary, to a temperature between 18.8-41.1°C
(66-100°F). 3. Remove the tape liner from the adhesive tape.
Important: Do not touch the adhesive surface.
4. Ensure that the molding is aligned with the body panel. Press the door side molding to the body
panel. 5. Hand roll the door side molding to the body in order to ensure proper adhesion.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information >
Service and Repair
Front Fender Liner: Service and Repair
Front Wheelhouse Liner Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair
).
3. Remove the push-pins from the inner wheelhouse liner. 4. Remove the inner wheelhouse liner
from the vehicle. 5. Remove the push-pins from the outer wheelhouse liner. 6. Remove the outer
wheelhouse liner (2).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information >
Service and Repair > Page 10036
1. Install the outer wheelhouse liner (2) to the vehicle. 2. Install the rearward push-pin into the outer
wheelhouse liner. 3. Install the remaining push-pins into the outer wheelhouse liner. 4. Install the
inner wheelhouse liner to the vehicle. 5. Install the push-pins into the inner wheelhouse liner. 6.
Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair). 7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information >
Service and Repair
Rear Fender Liner: Service and Repair
Pickup Box Wheelhouse Liner Replacement
Removal Procedure
Remove the push-in retainers that attach the liner to the vehicle.
Installation Procedure
Install the push-in retainers that attach the liner to the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 11-08-61-001A > Apr > 11 > Body Underbody Squeak/Creak/Crunch Noise
Body / Frame Mount Bushing: Customer Interest Body - Underbody Squeak/Creak/Crunch Noise
TECHNICAL
Bulletin No.: 11-08-61-001A
Date: April 14, 2011
Subject: Underbody Squeak/Creak/Crunch Noise During Slow Speed Maneuvers (Replace Body
Mount Cushions)
Models:
2004-2011 Chevrolet Colorado 2004-2011 GMC Canyon 2006-2010 HUMMER H3
Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate
Bulletin Number 11-08-61-001 (Section 08 - Body and Accessories).
Condition
Some customers may comment on a squeak/creak/crunch type noise coming from under the
vehicle while driving. This condition is most noticeable when driving at low speeds over uneven
surfaces such as driveway entrances or in parking structures.
Cause
This condition may be caused by friction between the upper and lower body mount cushion
assemblies.
Correction
A revised body mount cushion assembly is now available to correct this condition. The revised part
has an anti-friction coating that will eliminate the noise. Use the following steps to diagnose the
condition and install the required service part(s).
To diagnose this concern, use chassis ears to determine if the noise is coming from the body
mount cushion. If the source of the noise is determined to be caused by the body mount cushion,
replace all of the upper body mount cushion assemblies on the vehicle with the revised parts.
Use the following steps to install the revised cushion assemblies.
Important On HUMMER H3 models, it is necessary to disconnect the fuel fill pipe from the fuel tank
to prevent damage when lifting the body.
Note
On vehicles equipped with a front skid plate, it may be necessary to remove the skid plate from the
vehicle to access the front mounts.
1. Disconnect the front parking brake cable from the parking brake equalizer. Refer to Parking
Brake Lever Pedal Assembly Replacement in SI.
Warning
When you remove the body cushions, do NOT separate the frame from the body more than is
necessary (over 40 mm (1.57 in). Possible personal injury and damage to multiple parts may result
if you do not follow the guides outlined below:
^ Intermediate steering shaft - Do not allow the shaft to extend more than 25 mm (1 in).
^ Fuel tank filler hose - Do not stretch the hose excessively.
^ Tail/Turn signal lamp wiring/rear lamps junction block - Leave slack in the wires.
^ Park brake cable - Leave slack in the cable.
^ Body ground straps - Leave slack in the wire.
2. Replace all of the upper cushion assemblies on the vehicle. Refer to Drivetrain and Front
Suspension Frame Insulator Replacement in SI. 3. Reconnect the front parking brake cable to the
parking brake equalizer. Refer to Parking Brake Lever Pedal Assembly Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 11-08-61-001A > Apr > 11 > Body Underbody Squeak/Creak/Crunch Noise > Page 10050
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 11-08-61-001A > Apr > 11
> Body - Underbody Squeak/Creak/Crunch Noise
Body / Frame Mount Bushing: All Technical Service Bulletins Body - Underbody
Squeak/Creak/Crunch Noise
TECHNICAL
Bulletin No.: 11-08-61-001A
Date: April 14, 2011
Subject: Underbody Squeak/Creak/Crunch Noise During Slow Speed Maneuvers (Replace Body
Mount Cushions)
Models:
2004-2011 Chevrolet Colorado 2004-2011 GMC Canyon 2006-2010 HUMMER H3
Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate
Bulletin Number 11-08-61-001 (Section 08 - Body and Accessories).
Condition
Some customers may comment on a squeak/creak/crunch type noise coming from under the
vehicle while driving. This condition is most noticeable when driving at low speeds over uneven
surfaces such as driveway entrances or in parking structures.
Cause
This condition may be caused by friction between the upper and lower body mount cushion
assemblies.
Correction
A revised body mount cushion assembly is now available to correct this condition. The revised part
has an anti-friction coating that will eliminate the noise. Use the following steps to diagnose the
condition and install the required service part(s).
To diagnose this concern, use chassis ears to determine if the noise is coming from the body
mount cushion. If the source of the noise is determined to be caused by the body mount cushion,
replace all of the upper body mount cushion assemblies on the vehicle with the revised parts.
Use the following steps to install the revised cushion assemblies.
Important On HUMMER H3 models, it is necessary to disconnect the fuel fill pipe from the fuel tank
to prevent damage when lifting the body.
Note
On vehicles equipped with a front skid plate, it may be necessary to remove the skid plate from the
vehicle to access the front mounts.
1. Disconnect the front parking brake cable from the parking brake equalizer. Refer to Parking
Brake Lever Pedal Assembly Replacement in SI.
Warning
When you remove the body cushions, do NOT separate the frame from the body more than is
necessary (over 40 mm (1.57 in). Possible personal injury and damage to multiple parts may result
if you do not follow the guides outlined below:
^ Intermediate steering shaft - Do not allow the shaft to extend more than 25 mm (1 in).
^ Fuel tank filler hose - Do not stretch the hose excessively.
^ Tail/Turn signal lamp wiring/rear lamps junction block - Leave slack in the wires.
^ Park brake cable - Leave slack in the cable.
^ Body ground straps - Leave slack in the wire.
2. Replace all of the upper cushion assemblies on the vehicle. Refer to Drivetrain and Front
Suspension Frame Insulator Replacement in SI. 3. Reconnect the front parking brake cable to the
parking brake equalizer. Refer to Parking Brake Lever Pedal Assembly Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 11-08-61-001A > Apr > 11
> Body - Underbody Squeak/Creak/Crunch Noise > Page 10056
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Technical Service Bulletins > Page 10057
Body / Frame Mount Bushing: Service and Repair
Frame Cushion or Insulator Replacement
Removal Procedure
Support the frame with the hoist when you change the body mounts. If only one mount is changed,
loosen and lower the entire side on which the mount in question is being replaced.
1. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Use jack stands or the equivalent to support the body where the
mounts will be replaced.
3. Remove the bolt/cushion assembly at the number 1 and the number 2 body mount.
4. Remove the bolt/cushion assembly at the number 3 body mount, short wheel base vehicles. 5.
Remove the bolt/cushion assembly at the number 3 and the number 4 body mount, long wheel
base vehicles.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Technical Service Bulletins > Page 10058
6. Disconnect or remove any wiring harness or component that may interfere with the lowering of
the frame. 7. Lower the hoist in order to leave the body supported by the jack stands.
8. Remove the upper cushions at the number 1 and the number 2 body mount.
9. Remove the upper cushions at the number 3 body mount, short wheel base vehicles.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Technical Service Bulletins > Page 10059
10. Remove the upper cushions at the number 3 and the number 4 body mount, long wheel base
vehicles.
Installation Procedure
1. Install the upper cushions to the number 3 and the number 4 body mount, long wheel base
vehicles.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Technical Service Bulletins > Page 10060
2. Install the upper cushion to the number 3 body mount, short wheel base vehicles.
3. Install the upper cushions to the number 1 and the number 2 body mount. 4. Raise the hoist to
allow the body mount bolts to be installed. 5. Connect or install any wiring harness or component
that was removed to allow for the lowering of the frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Technical Service Bulletins > Page 10061
6. Install the bolt/cushion assembly to the number 1 and the number 2 body mount.
7. Install the bolt/cushion assembly to the number 3 body mount, short wheel base vehicles.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
8. Install the bolt/cushion assembly to the number 3 and the number 4 body mount, long wheel
base vehicles.
Tighten the bolts to 115 Nm (85 lb ft).
9. Remove the jack stands.
10. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair
> Crossmember Replacement
Cross-Member: Service and Repair Crossmember Replacement
Crossmember Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair).
2. Remove the crossmember mounting nuts and bolts. 3. Remove the crossmember from the
vehicle.
Installation Procedure
1. Install the crossmember to the vehicle. 2. Perform the following procedure before installing the
bolts.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair
> Crossmember Replacement > Page 10066
* Remove all traces of the original adhesive patch.
* Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry.
* Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the bolts and the nuts and tighten to 60 Nm (44 lb ft). 4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair
> Crossmember Replacement > Page 10067
Cross-Member: Service and Repair Transmission Support Crossmember Replacement
Transmission Support Crossmember Replacement (2WD)
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle
Lifting/Service and Repair). 2. Support the transmission with a suitable stand or jack.
3. Remove the nuts retaining the transmission mount to the transmission support. Refer to
Transmission Mount Replacement (2WD) (See:
Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Mount/Service and
Repair)Transmission Mount Replacement (4WD) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Transmission Mount/Service and Repair) for the 4L60E/4L65E
transmission or Transmission Mount Replacement (RPO Z71) (See: Transmission and
Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission
Mount Replacement (4WD) (See: Transmission and Drivetrain/Manual
Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount
Replacement (RPO Z85 and ZQ8) (See: Transmission and Drivetrain/Manual
Transmission/Transaxle/Transmission Mount/Service and Repair) for the Aisin AR5 transmission.
4. Raise the transmission.
5. Remove the vertical bolts retaining the transmission support to the frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair
> Crossmember Replacement > Page 10068
6. Remove the horizontal nuts and the bolts retaining the transmission support to the frame. 7.
Remove the transmission support from the frame.
Installation Procedure
1. Install the transmission support to the frame. 2. Loose install the horizontal nuts and the bolts
retaining the transmission support to the frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair
> Crossmember Replacement > Page 10069
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Loose install the vertical bolts retaining the transmission support to the frame.
* Tighten the horizontal nuts to 50 Nm (37 lb ft).
* Tighten the vertical bolts to 100 Nm (74 lb ft).
4. Lower the transmission.
5. Install the nuts to the transmission mount. Refer to Transmission Mount Replacement (2WD)
(See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount
Replacement (4WD) (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Transmission Mount/Service and Repair) for the 4L60E/4L65E
transmission or Transmission Mount Replacement (RPO Z71) (See: Transmission and
Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair )Transmission
Mount Replacement (4WD) (See: Transmission and Drivetrain/Manual
Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount
Replacement (RPO Z85 and ZQ8) (See: Transmission and Drivetrain/Manual
Transmission/Transaxle/Transmission Mount/Service and Repair) for the Aisin AR5 transmission.
6. Remove the stand or jack. 7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair
Skid Plate: Service and Repair
Engine Protection Shield Replacement
Removal Procedure
1. Remove the front shield bolts (1, 2). 2. Remove the front shield from the vehicle.
3. Remove the rear shield bolts (1, 2). 4. Remove the rear shield from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair >
Page 10073
1. Install the rear shield to the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the rear shield bolts (1) and tighten to 75 Nm (55 lb ft). 3. Install the rear shield bolts (2)
and tighten to 20 Nm (15 lb ft).
4. Install the front shield to the vehicle. 5. Install the front shield bolts (1) and tighten to 60 Nm (44
lb ft). 6. Install the front shield bolts (2) and tighten to 20 Nm (15 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair
Trailer Hitch: Service and Repair
Trailer Weight Distributor Hitch Platform Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair
Grille: Service and Repair
Grille Replacement
Removal Procedure
1. Open the hood. 2. Release the retainer on the daytime running lights (DRL), park lamp
assembly. 3. Remove the DRL, park lamp assembly. 4. Use a flat-bladed tool in order to release
the retainers that retain the grille to the body. 5. Lift the grille out of position. 6. Remove the grille
from the vehicle.
7. Remove the nuts retaining the grille bar (1) to the grille (2). 8. Remove the grille bar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 10080
Installation Procedure
1. Position the grille to the grille molding. 2. Using a Weller(R) model 8200 soldering gun, or
equivalent, equipped with a flat tip, use a circular motion around the heat stake.
1. Apply firm steady pressure to spread the heat stake material onto the grille panel to achieve a
proper weld. 2. Heat stake the grille to the grille molding at all heat stake locations.
3. Install the grille bar (1).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the grille bar retaining nuts. Tighten the nuts to 4 Nm (35 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 10081
5. Position the grille to the vehicle. 6. Position the grille onto the radiator support such that the
lower locating tabs are properly aligned. 7. Push the lower portion of the grille rearward until an
audible engagement of the retainers is heard. 8. Align the upper locating tabs of the grille with the
slots in the radiator support. 9. Install and fully seat the retaining clips into the radiator support.
10. Install the DRL, park lamp assembly. 11. Lower the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle
Carpet: Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle
INFORMATION
Bulletin No.: 06-00-89-029F
Date: April 27, 2010
Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather,
Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability
Models:
2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum
and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009
Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 06-00-89-029E (Section 00 - General Information).
To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the
upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which
can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care
should be taken because newspapers and garments may transfer color to the vehicle's interior.
Many of today's interiors are made with new low gloss materials. Permanent damage may result
from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and
fabric) for which they are not intended. Using non-approved products can actually set the stain to
the point that nothing can remove it.
Important
Do not use silicone or wax-based products or those containing organic solvents (such as naptha,
alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing
the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the
windshield and even make it difficult to see through the windshield under certain conditions.
- Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This
can cause damage to the vehicle's interior surfaces.
- Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with
degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt.
Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of
the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are
in the neutral-pH range and will maintain the best vehicle interior appearance. These products are
water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals.
Interior trim pieces on new vehicles, as well as service components, arrive with a protective film.
When removing the protective film, adhesive residue may be left on the trim panels/components.
The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing
adhesive residue without causing damage to the component.
Important
- If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the
residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the
pH neutral range, they won't leave behind soapy residue.
- On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be
treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this
bulletin for more information.
Effective cleaning steps for hard and/or plastic surfaces:
1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the
towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work
cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the
surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the
towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's
original luster.
Important Today's interiors are developed and intended to have a low-gloss appearance. It is
important to use only products which provide a low-gloss finish in order to maintain the interior's
integrity, customer appeal and satisfaction.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10087
Effective cleaning steps for fabric:
1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate
stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle
brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to
reduce or eliminate future staining.
Upholstery and Carpet Stains
When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you
determine which cleaner/formula works best on a particular stain. The chart lists many of the
common stains. Some complex stains may require the application of both stain removers, one after
the other, to remove both food-based oils and synthetic oils.
A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain
or material. This enables the dirt/stain to be completely removed from the material.
Leather Conditioner/Restorer
A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a
water-based product and contains essential emollients to restore suppleness, conditions and adds
luster without adding gloss. The restorer will also provide protection against re-staining.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10088
Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede
comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will
appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely
affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with
the restorer.
Extractor Machine and Concentrate
For difficult to clean materials or when cleaning a large area, the best results will be achieved when
using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N
627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released
a concentrate for use with the extractor machine.
Whichever extractor machine is used, it should meet the minimum specifications of the Ruby
Extractor:
Ruby Extractor Specifications:
- Pump PSI: 55
- Water Lift: 85"
- Hose Length: 10 ft
Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty.
Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in
the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The
water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry
time is greatly reduced due to less water on the fabric surface, the vacuum head making better
contact with the surface and the significant water lift capability of the machine.
Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help
remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions
listed on the container. The available concentrate helps to break the stain down and then the stain
is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to
remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions.
Dirt, grease and grime are more easily removed when the proper solution is used during the
extraction process.
Parts Information
Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles.
Available Equipment
Equipment is available by contacting 1-800-GMTOOLS.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10089
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10090
Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats
INFORMATION
Bulletin No.: 10-08-110-001
Date: March 30, 2010
Subject: Information on Proper Use of Floor Mats
Models:
2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X
GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM
vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly
may cause interference with the accelerator or brake pedal. Please review the following safety
guidelines regarding proper driver's side floor mat usage with the customer.
Warning
If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal
and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or
increased stopping distance which can cause a crash and injury. Make sure the floor mat does not
interfere with the accelerator or brake pedal.
- Do not flip the driver's floor mat over (in an effort to keep the floor mat clean)
- Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel)
- Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber
mats over carpeted floor mats)
- Only use floor mats that are designed specifically for your vehicle
- When using replacement mats, make certain the mats do not interfere with the accelerator or
brake pedal before driving the vehicle
If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is
installed correctly and according to the instructions.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10091
After installing floor mats, make certain they cannot move and do not interfere with the accelerator
or brake pedals.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10092
Carpet: Technical Service Bulletins Interior - Elimination Of Unwanted Odors
INFORMATION
Bulletin No.: 00-00-89-027E
Date: September 29, 2008
Subject: Eliminating Unwanted Odors in Vehicles
Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior
HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X
Supercede:
This bulletin is being revised to add model years and refine the instructions. Please discard
Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information).
Vehicle Odor Elimination
General Motors offers a product that may control or eliminate odors in the interior and luggage
compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic,
biodegradable odor remover. This odorless product has been shown to greatly reduce or remove
objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer
created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl,
leather, carpet and sound deadening materials. It may also be induced into HVAC modules and
instrument panel ducts (for the control of non-bacterial related odors).
Important:
This product leaves no residual scent and should not be sold as or considered an air freshener.
Product action may result in the permanent elimination of an odor and may be preferable to
customers with allergies who are sensitive to perfumes.
How to Use This Product
GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam
cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all
vehicle interiors. Do not wet or soak any interior surface that plain water would cause to
deteriorate, as this product will have the same effect. Also avoid letting this product come into
contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of,
or render GM Vehicle Care Odor Eliminator inert.
Note:
Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor
Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by
step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a
replacement set faxed or e-mailed to your dealership.
Instructions and cautions are printed on the bottle, but additional help is available. If you encounter
a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada,
1-800-977-4145) to obtain additional information and usage suggestions.
Important:
This product may effectively remove odors when directly contacting the odor source. It should be
used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the
root cause of the odor, and then the residual odor to permanently correct the vehicle condition.
Vehicle Waterleak Odor Elimination
STEP ONE:
Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water
soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor
source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle
interior by careful evaluation. Odor evaluation may need to be performed by multiple persons.
Another method of isolating an odor source is to remove and segregate interior trim and
components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist
in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated
separately to determine if the odor stays with the vehicle or the interior components. Odors that
stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak
at the windshield or standing water in the front foot well area caused mold/mildew to form on the
bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and
primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and
dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product
before reinstalling carpet or reassembling.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10093
The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used
properly. It must come into direct contact with the odor source. It should be used in conjunction with
diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after
odor root cause correction are:
STEP TWO:
^ Use the trigger spray head.
^ Put a drop of dish soap the size of a quarter in the bottom of a bottle.
^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with
tap water.
^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan)
STEP THREE:
The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and
upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting
(at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The
headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and
upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should
be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface.
STEP FOUR: (vehicle ventilation system treatment)
The ventilation system is generally the last step in the treatment of the vehicle.
a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per
vent).
b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting).
c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of
windshield)
d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents.
e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into
the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell
coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray
3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7
minutes.
Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited
is resolved without completing every step, the remaining steps do not need to be performed. If
these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.
Additional Suggestions to Increase Customer Satisfaction
Here are some additional ideas to benefit your dealership and to generate greater customer
enthusiasm for this product.
^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to
your used car trades; treat loaner and demo cars during service and at final sale to eliminate
smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of
your normal vehicle detailing service.
^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle
purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM
Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the
vehicle. Customers may find this product can be used for a host of recreational activities
associated with their new vehicle, such as deodorizing a boat they tow, or a camper.
^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase
dealership traffic as these superior quality products cannot be purchased in stores. Many
Dealerships have product displays at the parts counter. Consider additional displays in the
Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many
customers who purchase vehicles and receive regular maintenance at your dealership may never
visit the parts counter, and subsequently are not exposed to the variety and value that these
products offer.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10094
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles
Carpet: Service and Repair Eliminating Unwanted Odors in Vehicles
Eliminating Unwanted Odors in Vehicles
GM Vehicle Care Odor Eliminator, GM P/N 12378554 (Canadian P/N 88901678), may control or
eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic,
biodegradable, odorless product has been shown to greatly reduce or remove the following types
of odor:
* Objectionable smells of mold and mildew resulting from vehicle water leaks
* Customer created odors, such as smoke
You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound
deadening materials. You may also induce this product into HVAC modules and instrument panel
ducts for the control of non-bacterial related odors.
Important: This product leaves no residual scent and should not be used as an air freshener.
This product may result in the permanent elimination of an odor and may be preferable to
customers whose allergies make them sensitive to perfumes. This product may effectively remove
odors when directly contacting the odor source. In cases such as water leaks, use this product with
diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications
on the residual odor to permanently correct the vehicle condition.
How to Use this Product
* Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam
cleaners.
* Do not use on any interior surface that plain water would deteriorate, because this product will
have the same effect. Also avoid letting this product come into contact with vinegar or any acidic
substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator.
* Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor
Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by
step procedures for odor removal from water leaks.
* Instructions and cautions are printed on the bottle, but additional help is available.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles > Page 10097
Carpet: Service and Repair Floor Carpet Drying
Floor Carpet Drying
If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the
components:
* For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly.
* For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While
the carpet is out of the vehicle, dry the carpet using the method described below.
* For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry
the carpet using the method described below.
* For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method
described below.
Drying Method
1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess
moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as
possible. 3. Point a fan at the affected area and air dry the carpet.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles > Page 10098
Carpet: Service and Repair Floor Panel Carpet Replacement
Floor Panel Carpet Replacement
Removal Procedure
1. Remove the front seats. Refer to Split Bench Seat Replacement (See: Seats/Service and
Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket).
2. Remove the rear seats, if equipped. Refer to Rear Bench Seat Replacement (See:
Seats/Service and Repair/Rear Bench Seat Replacement). 3. Remove the storage bins, if
equipped. Refer to Rear Storage Compartment Replacement (See: Utility Storage
Compartment/Service and Repair). 4. Remove the jack and tool storage bracket. Refer to Jack and
Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 5. For extended
and crew cabs, remove the jack tools from the floor. 6. Remove the floor console, if equipped.
Refer to Console Replacement (Large w/Manual or Auto Transmission) (See: Console/Service and
Repair
)Console Replacement (Small w/Manual Transmission) (See: Console/Service and Repair).
7. Remove the lower center instrument panel (I/P) trim. Refer to Instrument Panel Lower Center
Trim Replacement (See: Dashboard / Instrument
Panel/Service and Repair).
8. Remove the front door sill plates. Refer to Front Side Door Sill Trim Plate Replacement (See:
Scuff Plate/Service and Repair). 9. Remove the left hinge pillar trim panel. Refer to Body Hinge
Pillar Trim Panel Replacement - Left Side (See: Trim Panel/Service and Repair).
10. Remove the right hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement Right Side (See: Trim Panel/Service and Repair). 11. Remove the rear door sill plates, if equipped.
Refer to Rear Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). 12.
Remove the lower center pillar trim panels, if equipped. Refer to Center Pillar Lower Trim Panel
Replacement (See: Trim Panel/Service and
Repair).
13. Remove the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab)
(See: Trim Panel/Service and Repair)Body Rear
Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Rear Trim
Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair).
14. Remove the lower body rear corner trim panels. Refer to Body Side Rear Lower Trim Panel
Replacement (Regular Cab) (See: Trim
Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim
Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See:
Trim Panel/Service and Repair).
15. Remove the carpet from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles > Page 10099
1. Position the carpet in the vehicle. 2. Install the lower body rear corner trim panels. Refer to Body
Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service
and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service
and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Trim
Panel/Service and Repair).
3. Install the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See:
Trim Panel/Service and Repair)Body Rear Trim
Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Rear Trim Panel
Replacement (Extended Cab) (See: Trim Panel/Service and Repair).
4. Install the lower center pillar trim panels, if equipped. Refer to Center Pillar Lower Trim Panel
Replacement (See: Trim Panel/Service and Repair
).
5. Install the rear door sill plates, if equipped. Refer to Rear Side Door Sill Trim Plate Replacement
(See: Scuff Plate/Service and Repair). 6. Install the left hinge pillar trim panel. Refer to Body Hinge
Pillar Trim Panel Replacement - Left Side (See: Trim Panel/Service and Repair). 7. Install the right
hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Trim
Panel/Service and Repair). 8. Install the front door sill plates. Refer to Front Side Door Sill Trim
Plate Replacement (See: Scuff Plate/Service and Repair). 9. Install the lower center I/P trim. Refer
to Instrument Panel Lower Center Trim Replacement (See: Dashboard / Instrument Panel/Service
and
Repair).
10. Install the floor console, if equipped. Refer to Console Replacement (Large w/Manual or Auto
Transmission) (See: Console/Service and Repair
)Console Replacement (Small w/Manual Transmission) (See: Console/Service and Repair).
11. For extended and crew cabs, install the jack tools to the floor. 12. Install the jack and tool
storage bracket. Refer to Jack and Tool Stowage Container Bracket Replacement (See:
Jack/Service and Repair). 13. Install the storage bins, if equipped. Refer to Rear Storage
Compartment Replacement (See: Utility Storage Compartment/Service and Repair). 14. Install the
rear seats, if equipped. Refer to Rear Bench Seat Replacement (See: Seats/Service and
Repair/Rear Bench Seat Replacement). 15. Install the front seats. Refer to Split Bench Seat
Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission)
Console: Service and Repair Console Replacement (Large w/Manual or Auto Transmission)
Console Replacement (Large w/Manual or Auto Transmission)
Removal Procedure
1. For regular cab vehicles, remove the passenger front bucket seat. Refer to Front Seat
Replacement - Bucket (See: Seats/Service and Repair/Front
Seat Replacement - Bucket).
2. For regular, extended and crew cab vehicles, remove the front bucket seat fasteners retaining
the floor console to the floor. Refer to Front Seat
Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket).
3. If the vehicle is equipped with a floor mounted shift lever, remove the shift lever bezel and boot.
4. Lift upward on the front and middle section of the console to release the retainers.
5. Remove the console from the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10104
Installation Procedure
1. Position the console to the floor panel. 2. Ensure the retainers are indexed to the corresponding
holes in the floor panel.
Important: Ensure the console bracket is positioned under the seat frame.
3. Push downward on the console to seat the retainers. 4. If the vehicle is equipped with a floor
mounted shift lever, install the shift lever bezel and boot. 5. Install the console bolts and if
necessary, install the front bucket seat. Refer to Front Seat Replacement - Bucket (See:
Seats/Service and
Repair/Front Seat Replacement - Bucket).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10105
Console: Service and Repair Console Replacement (Small w/Manual Transmission)
Console Replacement (Small w/Manual Transmission)
Removal Procedure
1. Release the retaining strips on the shift lever boot. 2. Remove the inside rear seat track bolts on
both front seats. 3. Lift up on the console to release the 4 retainers. 4. Remove the console from
the vehicle.
Installation Procedure
1. Position the console to the floor panel. 2. Ensure the retainers are indexed to the corresponding
holes in the floor panel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10106
3. Push downward on the console seating the retainers.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the seat track bolts on both front seats. Tighten the bolts to 53 Nm (39 lb ft). 5. Attach the
retaining strips on the shift lever bezel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10107
Console: Service and Repair Console Shift Lever Bezel Replacement
Console Shift Lever Bezel Replacement
Removal Procedure
1. Separate the retaining strips on the shift lever boot. 2. Lift upward on the shift lever bezel to
release the retaining tabs. 3. Lift the bezel and boot over the shift lever.
4. If necessary, remove the boot assembly from the bezel by releasing the wire retainer and
position locator (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10108
1. If necessary, install the boot to the bezel ensuring the position locator (1) is pointing forward.
2. Lower the bezel and boot over the shift lever. 3. Ensure the retaining tabs are properly indexed
to the console. 4. Push downward on the shift lever bezel to seat the retaining tabs. 5. Attach the
retaining strips on the shift lever boot.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10109
Console: Service and Repair Front Floor Console Armrest Replacement
Front Floor Console Armrest Replacement
Removal Procedure
1. Open the console armrest, revealing the lower compartment.
2. Remove the 3 screws (1) located on the upper hinge.
3. Remove the armrest from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10110
1. Position the armrest to the console.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the 3 screws (1) retaining the armrest to the upper hinge. Tighten the screws to 1.5 Nm
(15 lb in). 3. Close the armrest.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10111
Console: Service and Repair
Console Replacement (Large w/Manual or Auto Transmission)
Console Replacement (Large w/Manual or Auto Transmission)
Removal Procedure
1. For regular cab vehicles, remove the passenger front bucket seat. Refer to Front Seat
Replacement - Bucket (See: Seats/Service and Repair/Front
Seat Replacement - Bucket).
2. For regular, extended and crew cab vehicles, remove the front bucket seat fasteners retaining
the floor console to the floor. Refer to Front Seat
Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket).
3. If the vehicle is equipped with a floor mounted shift lever, remove the shift lever bezel and boot.
4. Lift upward on the front and middle section of the console to release the retainers.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10112
5. Remove the console from the vehicle.
Installation Procedure
1. Position the console to the floor panel. 2. Ensure the retainers are indexed to the corresponding
holes in the floor panel.
Important: Ensure the console bracket is positioned under the seat frame.
3. Push downward on the console to seat the retainers. 4. If the vehicle is equipped with a floor
mounted shift lever, install the shift lever bezel and boot. 5. Install the console bolts and if
necessary, install the front bucket seat. Refer to Front Seat Replacement - Bucket (See:
Seats/Service and
Repair/Front Seat Replacement - Bucket).
Console Replacement (Small w/Manual Transmission)
Console Replacement (Small w/Manual Transmission)
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10113
1. Release the retaining strips on the shift lever boot. 2. Remove the inside rear seat track bolts on
both front seats. 3. Lift up on the console to release the 4 retainers. 4. Remove the console from
the vehicle.
Installation Procedure
1. Position the console to the floor panel. 2. Ensure the retainers are indexed to the corresponding
holes in the floor panel. 3. Push downward on the console seating the retainers.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the seat track bolts on both front seats. Tighten the bolts to 53 Nm (39 lb ft). 5. Attach the
retaining strips on the shift lever bezel.
Console Shift Lever Bezel Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10114
Console Shift Lever Bezel Replacement
Removal Procedure
1. Separate the retaining strips on the shift lever boot. 2. Lift upward on the shift lever bezel to
release the retaining tabs. 3. Lift the bezel and boot over the shift lever.
4. If necessary, remove the boot assembly from the bezel by releasing the wire retainer and
position locator (1).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10115
1. If necessary, install the boot to the bezel ensuring the position locator (1) is pointing forward.
2. Lower the bezel and boot over the shift lever. 3. Ensure the retaining tabs are properly indexed
to the console. 4. Push downward on the shift lever bezel to seat the retaining tabs. 5. Attach the
retaining strips on the shift lever boot.
Front Floor Console Armrest Replacement
Front Floor Console Armrest Replacement
Removal Procedure
1. Open the console armrest, revealing the lower compartment.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10116
2. Remove the 3 screws (1) located on the upper hinge.
3. Remove the armrest from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10117
1. Position the armrest to the console.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the 3 screws (1) retaining the armrest to the upper hinge. Tighten the screws to 1.5 Nm
(15 lb in). 3. Close the armrest.
Front Floor Console Compartment Door Hinge Replacement
Front Floor Console Compartment Door Hinge Replacement
Removal Procedure
1. Remove the armrest. Refer to Front Floor Console Armrest Replacement (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10118
2. Remove the 3 screws (2) located on the lower hinge. 3. Remove the hinge from the vehicle.
Installation Procedure
1. Position the hinge to the console.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the 3 screws (2) retaining the armrest to the lower hinge. Tighten the screws to 1.5 Nm
(15 lb in). 3. Install the armrest. Refer to Front Floor Console Armrest Replacement (See: ).
Front Floor Console Storage Tray Replacement
Front Floor Console Storage Tray Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10119
Removal Procedure
1. Ensure the console tray is empty. 2. Lift upward on the console tray to release the retaining tabs.
3. Remove the console tray from the vehicle.
Installation Procedure
1. Position the tray to the console. 2. Ensure the retaining tabs are indexed to the corresponding
holes in the console. 3. Push downward on the tray seating the retaining tabs.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations).
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Warning
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR
deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power
to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG
warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See:
Diagrams/Electrical Diagrams/Air Bag Systems) or
Electrical Center Identification Views (See: Maintenance/Fuses and Circuit
Breakers/Fuse/Application and ID).
4. Wait 1 minute before working on the system.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Page 10124
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to
SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical
Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and
ID).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to
Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
4. Wait 1 minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer
to Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information
> Service and Repair > Instrument Panel Compartment Door Latch Replacement
Glove Compartment: Service and Repair Instrument Panel Compartment Door Latch Replacement
Instrument Panel Compartment Door Latch Replacement
Removal Procedure
1. Open the instrument panel (I/P) storage compartment.
2. Remove the screws retaining the storage compartment handle assembly. 3. Remove the handle
assembly from the vehicle.
Installation Procedure
1. Install the handle assembly the storage compartment.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information
> Service and Repair > Instrument Panel Compartment Door Latch Replacement > Page 10129
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the screws retaining the handle assembly to the storage compartment. Tighten the screws
to 3 Nm (27 lb in). 3. Ensure the handle assembly is working properly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information
> Service and Repair > Instrument Panel Compartment Door Latch Replacement > Page 10130
Glove Compartment: Service and Repair Instrument Panel Compartment Door Replacement
Instrument Panel Compartment Door Replacement
Removal Procedure
1. Remove the instrument panel (I/P) storage compartment assembly. Refer to Instrument Panel
Storage Compartment Replacement (See:
Dashboard / Instrument Panel/Service and Repair).
2. Remove the screws retaining the storage compartment back panel.
3. Remove the back panel from the storage compartment.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information
> Service and Repair > Instrument Panel Compartment Door Latch Replacement > Page 10131
1. Install the back panel to the storage compartment.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the screws retaining the storage compartment back panel. Tighten the screws to 3 Nm (27
lb in). 3. Install the instrument panel (I/P) storage compartment assembly. Refer to Instrument
Panel Storage Compartment Replacement (See: Dashboard /
Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information
> Service and Repair > Instrument Panel Compartment Door Latch Replacement > Page 10132
Glove Compartment: Service and Repair Instrument Panel Storage Compartment Replacement
Instrument Panel Storage Compartment Replacement
Removal Procedure
1. Remove the screws retaining the instrument panel (I/P) compartment assembly to the I/P. 2.
Open the I/P compartment door. 3. Remove the I/P compartment assembly from the vehicle.
Installation Procedure
1. Position the I/P compartment assembly to the I/P. 2. Close and fully latch the I/P compartment
door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information
> Service and Repair > Instrument Panel Compartment Door Latch Replacement > Page 10133
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the fasteners retaining the I/P compartment assembly to the I/P. Tighten the fasteners to 3
Nm (27 lb in). 4. Ensure the alignment of the door allows for proper operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab)
Headliner: Service and Repair Headlining Trim Panel Replacement (Crew Cab)
Headlining Trim Panel Replacement (Crew Cab)
Warning
Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner
or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim.
Failure to do so could result in personal injury.
Caution: Use care when working around the head curtain inflator module. Sharp tools may
puncture the curtain airbag. If the head curtain inflator module is damaged in any way, it must be
replaced.
Caution: If a vehicle is equipped with a head curtain inflator module ensure that the inflator module
and tether are undamaged. If tether or curtain airbag are damaged in any way, they must be
replaced.
Removal Procedure
1. Remove the right front door. Refer to Front Side Door Replacement (See: Doors, Hood and
Trunk/Doors/Front Door/Service and Repair). 2. Remove the front seats. Refer to Split Bench Seat
Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket).
3. Remove the rear seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and
Repair/Rear Bench Seat Replacement). 4. Remove the windshield garnish moldings. Refer to
Windshield Pillar Garnish Molding Replacement (See: Trim Panel/Service and Repair).
5. Disconnect the headliner harness (1) from the body harness (2). 6. Remove the lower center
pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Trim Panel/Service
and Repair). 7. Remove the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel
Replacement (See: Trim Panel/Service and Repair). 8. Remove the lower body rear corner trim
panels. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Trim
Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim
Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See:
Trim Panel/Service and Repair).
9. Remove the upper body rear corner trim panels. Refer to Body Side Upper Trim Panel
Replacement (Regular Cab, Extended Cab) (See: Trim
Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Trim
Panel/Service and Repair).
10. Remove the dome lamp. Refer to Dome Lamp Replacement (See: Lighting and Horns/Dome
Lamp/Service and Repair). 11. Remove the sunshades. Refer to Sunshade Replacement (See:
Sun Visor/Service and Repair). 12. Remove the assist handles and the driver assist handle or
assist handle blank. Refer to Assist Handle Replacement (See: Passenger Assist
Handle/Service and Repair).
13. Remove the coat hooks. Refer to Coat Hook Replacement (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10138
14. Tilt the steering wheel to the full down position. 15. If equipped with a manual transmission,
place the transmission in 2nd gear and remove the shift knob handle. 16. Remove the 2 push pins
securing the headliner to the row bow. 17. Remove the 2 rear push pins from the headliner.
Replace any damaged push pin spacers. 18. Lower the forward edge of the headliner. 19. Standing
at the left front door, grasp the headliner at the dome lamp opening and at the headliner's left edge.
20. Slide the headliner forward and under the steering wheel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10139
21. Rotate the forward edge of the headliner towards the right front door opening ensuring that the
left edge of the headliner is behind the shift knob
stem.
22. Remove the headliner from the vehicle through the right front door opening.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10140
1. Install the headliner in the vehicle through the right front door opening, rear edge first.
2. Slid the headliner into the vehicle towards the left side of the cab ensuring that the left edge of
the headliner is behind the shift knob stem.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10141
3. Rotate the rear edge of the headliner towards the rear of the cab with the forward edge of the
headliner under the steering wheel. 4. Ensure that the roof rail air bag tethers will not be obstructed
by the installed headliner. 5. Raise the headliner into position and install the 2 rear push pins into
the roof. 6. Install the 2 push pins securing the headliner to the row bow. 7. Install the headliner
above the door weather strips. 8. Install the inboard sunshade retainers. Refer to Sunshade
Replacement (See: Sun Visor/Service and Repair). 9. Install the sunshades. Refer to Sunshade
Replacement (See: Sun Visor/Service and Repair).
10. Install the assist handles and the driver assist handle or assist handle blank. Refer to Assist
Handle Replacement (See: Passenger Assist
Handle/Service and Repair).
11. Install the coat hooks. Refer to Coat Hook Replacement (See: Service and Repair). 12. Install
the dome lamp. Refer to Dome Lamp Replacement (See: Lighting and Horns/Dome Lamp/Service
and Repair). 13. Install the upper body rear corner trim panels. Refer to Body Side Upper Trim
Panel Replacement (Regular Cab, Extended Cab) (See: Trim
Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Trim
Panel/Service and Repair).
14. Install the lower body rear corner trim panels. Refer to Body Side Rear Lower Trim Panel
Replacement (Regular Cab) (See: Trim Panel/Service
and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service
and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Trim
Panel/Service and Repair).
15. Install the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement
(See: Trim Panel/Service and Repair). 16. Install the lower center pillar trim panel. Refer to Center
Pillar Lower Trim Panel Replacement (See: Trim Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10142
17. Connect the headliner harness (1) to the body harness (2). 18. Install the windshield garnish
moldings. Refer to Windshield Pillar Garnish Molding Replacement (See: Trim Panel/Service and
Repair). 19. Install the rear seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and
Repair/Rear Bench Seat Replacement). 20. Install the front seats. Refer to Split Bench Seat
Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket).
21. Install the right front door. Refer to Front Side Door Replacement (See: Doors, Hood and
Trunk/Doors/Front Door/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10143
Headliner: Service and Repair Headlining Trim Panel Replacement (Extended Cab)
Headlining Trim Panel Replacement (Extended Cab)
Warning
Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner
or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim.
Failure to do so could result in personal injury.
Caution: Use care when working around the head curtain inflator module. Sharp tools may
puncture the curtain airbag. If the head curtain inflator module is damaged in any way, it must be
replaced.
Caution: If a vehicle is equipped with a head curtain inflator module ensure that the inflator module
and tether are undamaged. If tether or curtain airbag are damaged in any way, they must be
replaced.
Removal Procedure
1. Remove the windshield garnish moldings. Refer to Windshield Pillar Garnish Molding
Replacement (See: Trim Panel/Service and Repair).
2. Disconnect the headliner harness (1) from the body harness (2). 3. Remove the rear door striker
trim cover. Refer to Rear Side Door Latch Striker Cover Replacement (Extended Cab) (See: Trim
Panel/Service
and Repair).
4. Remove the rear seat back cushions. Refer to Rear Seat Back Cushion Replacement (Extended
Cab) (See: Seats/Seat Back/Service and
Repair/Rear Seat Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion
Replacement (Crew Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion
Replacement (Crew Cab)).
5. Remove the rear folding seats. Refer to Folding Seat Replacement (Extended Cab) (See:
Seats/Service and Repair/Folding Seat Replacement
(Extended Cab)).
6. Remove the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab)
(See: Trim Panel/Service and Repair)Body Rear
Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Rear Trim
Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair).
7. Remove the lower body rear corner trim panels. Refer to Body Side Rear Lower Trim Panel
Replacement (Regular Cab) (See: Trim
Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim
Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See:
Trim Panel/Service and Repair).
8. Remove the upper body rear corner trim panels. Refer to Body Side Upper Trim Panel
Replacement (Regular Cab, Extended Cab) (See: Trim
Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Trim
Panel/Service and Repair).
9. Remove the dome lamp. Refer to Dome Lamp Replacement (See: Lighting and Horns/Dome
Lamp/Service and Repair).
10. Remove the sunshades. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair).
11. Remove the passenger assist handle and the driver assist handle or assist handle blank. Refer
to Assist Handle Replacement (See: Passenger
Assist Handle/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10144
12. Remove the coat hooks. Refer to Coat Hook Replacement (See: Service and Repair).
13. Tilt the steering wheel to the full down position. 14. If equipped with a manual transmission,
place the transmission in 2nd gear and remove the shift knob handle. 15. Remove the 2 push pins
securing the headliner to the row bow. 16. Remove the 2 rear push pins from the headliner.
Replace any damaged push pin spacers. 17. Lower the forward edge of the headliner. 18. Standing
at the left front door, grasp the headliner at the dome lamp opening and at the headliner's left edge.
19. Slide the headliner forward and under the steering wheel. 20. Rotate the forward edge of the
headliner towards the right-hand door opening. 21. Remove the headliner from the vehicle through
the door opening.
Installation Procedure
1. Install the headliner in the vehicle through the right-hand door opening, rear edge first. 2. Slid the
headliner into the vehicle towards the left side of the cab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10145
3. Rotate the rear edge of the headliner towards the rear of the cab with the forward edge of the
headliner under the steering wheel. 4. Ensure that the roof rail air bag tethers will not be obstructed
by the installed headliner. 5. Raise the headliner into position and install the 2 rear push pins into
the roof. 6. Install the 2 push pins securing the headliner to the row bow. 7. Install the headliner
above the door weather strips. 8. Install the inboard sunshade retainers. Refer to Sunshade
Replacement (See: Sun Visor/Service and Repair). 9. Install the sunshades. Refer to Sunshade
Replacement (See: Sun Visor/Service and Repair).
10. Install the passenger assist handle and the driver assist handle or assist handle blank. Refer to
Assist Handle Replacement (See: Passenger Assist
Handle/Service and Repair).
11. Install the coat hooks. Refer to Coat Hook Replacement (See: Service and Repair). 12. Install
the dome lamp. Refer to Dome Lamp Replacement (See: Lighting and Horns/Dome Lamp/Service
and Repair). 13. Install the upper body rear corner trim panels. Refer to Body Side Upper Trim
Panel Replacement (Regular Cab, Extended Cab) (See: Trim
Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Trim
Panel/Service and Repair).
14. Install the lower body rear corner trim panels. Refer to Body Side Rear Lower Trim Panel
Replacement (Regular Cab) (See: Trim Panel/Service
and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service
and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Trim
Panel/Service and Repair).
15. Install the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See:
Trim Panel/Service and Repair)Body Rear Trim
Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Rear Trim Panel
Replacement (Extended Cab) (See: Trim Panel/Service and Repair).
16. Install the rear folding seats. Refer to Folding Seat Replacement (Extended Cab) (See:
Seats/Service and Repair/Folding Seat Replacement
(Extended Cab)).
17. Install the rear seat back cushions. Refer to Rear Seat Back Cushion Replacement (Extended
Cab) (See: Seats/Seat Back/Service and Repair/Rear
Seat Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew
Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew
Cab)).
18. Install the rear door striker trim cover. Refer to Rear Side Door Latch Striker Cover
Replacement (Extended Cab) (See: Trim Panel/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10146
19. Connect the headliner harness (1) to the body harness (2). 20. Install the windshield garnish
moldings. Refer to Windshield Pillar Garnish Molding Replacement (See: Trim Panel/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10147
Headliner: Service and Repair Headlining Trim Panel Replacement (Regular Cab)
Headlining Trim Panel Replacement (Regular Cab)
Warning
Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner
or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim.
Failure to do so could result in personal injury.
Caution: Use care when working around the head curtain inflator module. Sharp tools may
puncture the curtain airbag. If the head curtain inflator module is damaged in any way, it must be
replaced.
Caution: If a vehicle is equipped with a head curtain inflator module ensure that the inflator module
and tether are undamaged. If tether or curtain airbag are damaged in any way, they must be
replaced.
Removal Procedure
1. Remove the front seats. Refer to Split Bench Seat Replacement (See: Seats/Service and
Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket).
2. Remove the windshield garnish moldings. Refer to Windshield Pillar Garnish Molding
Replacement (See: Trim Panel/Service and Repair).
3. Disconnect the headliner harness (1) from the body harness (2). 4. Remove the lower body rear
corner trim panels. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See:
Trim
Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim
Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See:
Trim Panel/Service and Repair).
5. Remove the upper body rear corner trim panels. Refer to Body Side Upper Trim Panel
Replacement (Regular Cab, Extended Cab) (See: Trim
Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Trim
Panel/Service and Repair).
6. Remove the dome lamp. Refer to Dome Lamp Replacement (See: Lighting and Horns/Dome
Lamp/Service and Repair). 7. Remove the sunshades. Refer to Sunshade Replacement (See: Sun
Visor/Service and Repair). 8. Remove the passenger assist handle and the driver assist handle or
assist handle blank. Refer to Assist Handle Replacement (See: Passenger
Assist Handle/Service and Repair).
9. Remove the coat hook. Refer to Coat Hook Replacement (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10148
10. Tilt the steering wheel to the full down position. 11. If equipped with a manual transmission,
place the transmission in 2nd gear and remove the shift knob handle. 12. Remove the 2 push pins
securing the headliner to the row bow. 13. Remove the rear push pin from the headliner. Replace
any damaged push pin spacers. 14. Lower the forward edge of the headliner. 15. Standing at the
left front door, grasp the headliner at the dome lamp opening and at the headliner left edge.
16. Slide the headliner forward and under the steering wheel. 17. Rotate the forward edge of the
headliner towards the right-hand door opening. 18. Remove the headliner from the vehicle through
the door opening.
Installation Procedure
1. Install the headliner in the vehicle through the right-hand door opening, rear edge first. 2. Slide
the headliner into the vehicle towards the left side of the cab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10149
3. Rotate the rear edge of the headliner towards the rear of the cab with the forward edge of the
headliner under the steering wheel. 4. Ensure that the roof rail air bag tethers will not be obstructed
by the installed headliner. 5. Raise the headliner into position and install the rear push pin into the
roof. 6. Install the 6 push pins securing the headliner to the row bow. 7. Install the headliner above
the door weather strips. 8. Install the inboard sunshade retainers. Refer to Sunshade Replacement
(See: Sun Visor/Service and Repair). 9. Install the sunshades. Refer to Sunshade Replacement
(See: Sun Visor/Service and Repair).
10. Install the passenger assist handle and the driver assist handle or assist handle blank. Refer to
Assist Handle Replacement (See: Passenger Assist
Handle/Service and Repair).
11. Install the coat hook. Refer to Coat Hook Replacement (See: Service and Repair). 12. Install
the dome lamp. Refer to Dome Lamp Replacement (See: Lighting and Horns/Dome Lamp/Service
and Repair). 13. Install the upper body rear corner trim panels. Refer to Body Side Upper Trim
Panel Replacement (Regular Cab, Extended Cab) (See: Trim
Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Trim
Panel/Service and Repair).
14. Install the lower body rear corner trim panels. Refer to Body Side Rear Lower Trim Panel
Replacement (Regular Cab) (See: Trim Panel/Service
and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service
and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Trim
Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10150
15. Connect the headliner harness (1) to the body harness (2). 16. Install the windshield garnish
moldings. Refer to Windshield Pillar Garnish Molding Replacement (See: Trim Panel/Service and
Repair). 17. Install the front seats. Refer to Split Bench Seat Replacement (See: Seats/Service and
Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component
Information > Service and Repair
Passenger Assist Handle: Service and Repair
Assist Handle Replacement
Removal Procedure
1. Pull down the assist handle to reveal the 2 service holes.
2. Remove the screws and washers securing the assist handle to the retaining clip. 3. Remove the
assist handle from the vehicle. 4. If replacing the entire assist handle assembly, Remove the
retaining clips from the sheet metal.
Installation Procedure
1. Position the assist handle over the retaining clips.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component
Information > Service and Repair > Page 10154
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the assist handle by installing 2 screws and washers into the retaining clips. Tighten the
assist handle screws to 1.2 Nm (10 lb in).
3. In replacing the entire coat hook assembly, press the coat hook and the retaining clip as an
assembly into the sheet metal opening until the clip
locks into position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information >
Service and Repair > Front Side Door Sill Trim Plate Replacement
Scuff Plate: Service and Repair Front Side Door Sill Trim Plate Replacement
Front Side Door Sill Trim Plate Replacement
Removal Procedure
1. Grasp the front door sill plate and pull the panel away from the body to release the fasteners. 2.
Remove any fasteners that may have pulled away from the panel and reinstall them to the back of
the panel. 3. Slide the plate inward so the plate unhooks from the door frame. 4. Remove the front
door sill plate from the vehicle.
Installation Procedure
1. Position the front door sill plate over the pillar and door sill. 2. Ensure that the sill plate fasteners
are aligned with the holes in the body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information >
Service and Repair > Front Side Door Sill Trim Plate Replacement > Page 10159
3. Install the sill plate by pushing firmly against the body to seat the fasteners.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information >
Service and Repair > Front Side Door Sill Trim Plate Replacement > Page 10160
Scuff Plate: Service and Repair Rear Side Door Sill Trim Plate Replacement
Rear Side Door Sill Trim Plate Replacement
Removal Procedure
1. Grasp the rear door sill plate and pull the panel away from the body to release the fasteners. 2.
Remove any fasteners that may have pulled away from the panel and reinstall them to the back of
the panel. 3. Slide the plate inward so the plate unhooks from the door frame. 4. Remove the rear
door sill plate from the vehicle.
Installation Procedure
1. Position the rear door sill plate over the pillar and door sill. 2. Ensure that the sill plate fasteners
are aligned with the holes in the body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information >
Service and Repair > Front Side Door Sill Trim Plate Replacement > Page 10161
3. Install the sill plate by pushing firmly against the body to seat the fasteners.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service
and Repair
Sun Visor: Service and Repair
Sunshade Replacement
Removal Procedure
1. Remove the 2 screws and washers (4) securing the sunshade (1) to the roof. 2. Remove the
sunshade assembly. 3. Remove the screw and washer (3) securing the sunshade retainer (2) to
the roof. 4. Remove the sunshade retainer.
Installation Procedure
1. Install the sunshade retainer.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service
and Repair > Page 10165
2. Install the screw and washer (3) securing the sunshade retainer (2) to the roof. Tighten the
sunshade retainer screw to 1.2 Nm (10 lb in). 3. Install the sunshade assembly to the roof with 2
screws and washers. Tighten the sunshade screws to 1.2 Nm (10 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side
Trim Panel: Service and Repair Body Hinge Pillar Trim Panel Replacement - Left Side
Body Hinge Pillar Trim Panel Replacement - Left Side
Removal Procedure
1. Remove the left front door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement
(See: Scuff Plate/Service and Repair). 2. Grasp the left hinge pillar trim panel and gently pull the
panel away from the body to release the fasteners. 3. Remove any fasteners that may have pulled
away from the panel and reinstall them to the back of the panel. 4. Slide the panel forward so the
panel unhooks from around the front door frame. 5. Remove the left hinge pillar trim panel from the
vehicle.
Installation Procedure
1. Position the left hinge pillar trim panel over the pillar and door sill.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10170
2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel by
pushing firmly against the body to seat the panel fasteners. 4. Install the left front door sill trim
plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10171
Trim Panel: Service and Repair Body Hinge Pillar Trim Panel Replacement - Right Side
Body Hinge Pillar Trim Panel Replacement - Right Side
Removal Procedure
1. Remove the right front door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement
(See: Scuff Plate/Service and Repair). 2. Grasp the right hinge pillar trim panel and gently pull the
panel away from the body to release the fasteners. 3. Remove any fasteners that may have pulled
away from the panel and reinstall them to the back of the panel. 4. Slide the panel forward so the
panel unhooks from around the front door frame. 5. Remove the right hinge pillar trim panel from
the vehicle.
Installation Procedure
1. Position the right hinge pillar trim panel over the pillar and door sill.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10172
2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel by
pushing firmly against the body to seat the panel fasteners. 4. Install the right front door sill trim
plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10173
Trim Panel: Service and Repair Body Rear Trim Panel Replacement (Crew Cab)
Body Rear Trim Panel Replacement (Crew Cab)
Removal Procedure
1. Remove the rear seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and
Repair/Rear Bench Seat Replacement). 2. Remove the jack and tool storage bracket. Refer to Jack
and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair).
3. Remove the rear shoulder belt guide.
4. Grasp the lower edge of the body rear trim panel and pull to release the fasteners from the sheet
metal. 5. Raise the panel to unhook it from the sheet metal along the lower edge of the rear
window. 6. Remove any fasteners that may have pulled away from the panel and reinstall them to
the back of the panel. 7. Remove the body rear trim panel from the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10174
Installation Procedure
1. Hook the body rear trim panel in the sheet metal along the lower edge of the rear window. 2.
Install the panel by pushing firmly against the body to seat the panel fasteners.
3. Install the rear shoulder belt guide. 4. Install the jack and tool storage bracket. Refer to Jack and
Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 5. Install the rear
seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and Repair/Rear Bench Seat
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10175
Trim Panel: Service and Repair Body Rear Trim Panel Replacement (Extended Cab)
Body Rear Trim Panel Replacement (Extended Cab)
Removal Procedure
1. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Extended Cab)
(See: Seats/Seat Back/Service and Repair/Rear Seat
Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab)
(See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)).
2. Remove the folding seat. Refer to Folding Seat Replacement (Extended Cab) (See:
Seats/Service and Repair/Folding Seat Replacement
(Extended Cab)).
3. Remove the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket
Replacement (See: Jack/Service and Repair).
4. Remove the rear shoulder belt guide.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10176
5. Grasp the lower edge of the body rear trim panel and pull to release the fasteners from the sheet
metal. 6. Raise the panel to unhook it from the sheet metal along the lower edge of the rear
window. 7. Remove any fasteners that may have pulled away from the panel and reinstall them to
the back of the panel. 8. Remove the body rear trim panel from the vehicle.
Installation Procedure
1. Hook the body rear trim panel in the sheet metal along the lower edge of the rear window. 2.
Install the panel by pushing firmly against the body to seat the panel fasteners.
3. Install the rear shoulder belt guide. 4. Install the jack and tool storage bracket. Refer to Jack and
Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 5. Install the folding
seat. Refer to Folding Seat Replacement (Extended Cab) (See: Seats/Service and Repair/Folding
Seat Replacement (Extended
Cab)).
6. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Extended Cab) (See:
Seats/Seat Back/Service and Repair/Rear Seat
Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab)
(See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10177
Trim Panel: Service and Repair
Body Hinge Pillar Trim Panel Replacement - Left Side
Body Hinge Pillar Trim Panel Replacement - Left Side
Removal Procedure
1. Remove the left front door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement
(See: Scuff Plate/Service and Repair). 2. Grasp the left hinge pillar trim panel and gently pull the
panel away from the body to release the fasteners. 3. Remove any fasteners that may have pulled
away from the panel and reinstall them to the back of the panel. 4. Slide the panel forward so the
panel unhooks from around the front door frame. 5. Remove the left hinge pillar trim panel from the
vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10178
1. Position the left hinge pillar trim panel over the pillar and door sill. 2. Ensure that the panel
fasteners are aligned with the holes in the body. 3. Install the panel by pushing firmly against the
body to seat the panel fasteners. 4. Install the left front door sill trim plate. Refer to Front Side Door
Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair).
Body Hinge Pillar Trim Panel Replacement - Right Side
Body Hinge Pillar Trim Panel Replacement - Right Side
Removal Procedure
1. Remove the right front door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement
(See: Scuff Plate/Service and Repair). 2. Grasp the right hinge pillar trim panel and gently pull the
panel away from the body to release the fasteners. 3. Remove any fasteners that may have pulled
away from the panel and reinstall them to the back of the panel. 4. Slide the panel forward so the
panel unhooks from around the front door frame. 5. Remove the right hinge pillar trim panel from
the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10179
1. Position the right hinge pillar trim panel over the pillar and door sill. 2. Ensure that the panel
fasteners are aligned with the holes in the body. 3. Install the panel by pushing firmly against the
body to seat the panel fasteners. 4. Install the right front door sill trim plate. Refer to Front Side
Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair).
Body Rear Trim Panel Replacement (Crew Cab)
Body Rear Trim Panel Replacement (Crew Cab)
Removal Procedure
1. Remove the rear seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and
Repair/Rear Bench Seat Replacement). 2. Remove the jack and tool storage bracket. Refer to Jack
and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair).
3. Remove the rear shoulder belt guide.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10180
4. Grasp the lower edge of the body rear trim panel and pull to release the fasteners from the sheet
metal. 5. Raise the panel to unhook it from the sheet metal along the lower edge of the rear
window. 6. Remove any fasteners that may have pulled away from the panel and reinstall them to
the back of the panel. 7. Remove the body rear trim panel from the vehicle.
Installation Procedure
1. Hook the body rear trim panel in the sheet metal along the lower edge of the rear window. 2.
Install the panel by pushing firmly against the body to seat the panel fasteners.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10181
3. Install the rear shoulder belt guide. 4. Install the jack and tool storage bracket. Refer to Jack and
Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 5. Install the rear
seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and Repair/Rear Bench Seat
Replacement).
Body Rear Trim Panel Replacement (Extended Cab)
Body Rear Trim Panel Replacement (Extended Cab)
Removal Procedure
1. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Extended Cab)
(See: Seats/Seat Back/Service and Repair/Rear Seat
Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab)
(See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)).
2. Remove the folding seat. Refer to Folding Seat Replacement (Extended Cab) (See:
Seats/Service and Repair/Folding Seat Replacement
(Extended Cab)).
3. Remove the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket
Replacement (See: Jack/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10182
4. Remove the rear shoulder belt guide.
5. Grasp the lower edge of the body rear trim panel and pull to release the fasteners from the sheet
metal. 6. Raise the panel to unhook it from the sheet metal along the lower edge of the rear
window. 7. Remove any fasteners that may have pulled away from the panel and reinstall them to
the back of the panel. 8. Remove the body rear trim panel from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10183
1. Hook the body rear trim panel in the sheet metal along the lower edge of the rear window. 2.
Install the panel by pushing firmly against the body to seat the panel fasteners.
3. Install the rear shoulder belt guide. 4. Install the jack and tool storage bracket. Refer to Jack and
Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 5. Install the folding
seat. Refer to Folding Seat Replacement (Extended Cab) (See: Seats/Service and Repair/Folding
Seat Replacement (Extended
Cab)).
6. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Extended Cab) (See:
Seats/Seat Back/Service and Repair/Rear Seat
Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab)
(See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)).
Body Rear Trim Panel Replacement (Regular Cab)
Body Rear Trim Panel Replacement (Regular Cab)
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10184
1. Remove the front seats. Refer to Front Seat Replacement - Bucket (See: Seats/Service and
Repair/Front Seat Replacement - Bucket) or Split
Bench Seat Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement).
2. Remove the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket
Replacement (See: Jack/Service and Repair).
3. Remove the rear shoulder belt guide.
4. Grasp the lower edge of the body rear trim panel and pull to release the fasteners from the sheet
metal. 5. Raise the panel to unhook it from the sheet metal along the lower edge of the rear
window. 6. Remove any fasteners that may have pulled away from the panel and reinstall them to
the back of the panel. 7. Remove the body rear trim panel from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10185
1. Hook the body rear trim panel in the sheet metal along the lower edge of the rear window. 2.
Install the panel by pushing firmly against the body to seat the panel fasteners.
3. Install the rear shoulder belt guide. 4. Install the jack and tool storage bracket. Refer to Jack and
Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 5. Remove the
front seats. Refer to Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat
Replacement - Bucket) or Split
Bench Seat Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement).
Body Side Rear Lower Trim Panel Replacement (Crew Cab)
Body Side Rear Lower Trim Panel Replacement (Crew Cab)
Removal Procedure
1. Remove the rear door sill plates. Refer to Rear Side Door Sill Trim Plate Replacement (See:
Scuff Plate/Service and Repair). 2. Remove the rear seat. Refer to Rear Bench Seat Replacement
(See: Seats/Service and Repair/Rear Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10186
3. Remove the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab)
(See: )Body Rear Trim Panel Replacement (Regular
Cab) (See: )Body Rear Trim Panel Replacement (Extended Cab) (See: ).
4. Grasp the lower body rear corner trim panel and gently pull the panel (1) away from the body to
release the fasteners. 5. Remove any fasteners that may have pulled away from the panel and
reinstall them to the back of the panel. 6. Slide the panel forward so the panel unhooks from
around the rear door frame. 7. Remove the lower body rear corner trim panel from the vehicle.
Installation Procedure
1. Position the lower body rear corner trim panel (1) so that the front edge hooks around the rear
door frame. 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the
panel by pushing firmly against the body to seat the panel fasteners. 4. Install the body rear trim
panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: )Body Rear Trim Panel
Replacement (Regular
Cab) (See: )Body Rear Trim Panel Replacement (Extended Cab) (See: ).
5. Install the rear seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and
Repair/Rear Bench Seat Replacement). 6. Install the rear door sill plates. Refer to Rear Side Door
Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10187
Body Side Rear Lower Trim Panel Replacement (Extended Cab)
Body Side Rear Lower Trim Panel Replacement (Extended Cab)
Removal Procedure
1. Remove the rear door sill plates. Refer to Rear Side Door Sill Trim Plate Replacement (See:
Scuff Plate/Service and Repair). 2. Remove the rear seat back. Refer to Rear Seat Back Cushion
Replacement (Extended Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat
Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab)
(See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)).
3. Remove the rear folding seat. Refer to Folding Seat Replacement (Extended Cab) (See:
Seats/Service and Repair/Folding Seat Replacement
(Extended Cab)).
4. Remove the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab)
(See: )Body Rear Trim Panel Replacement (Regular
Cab) (See: )Body Rear Trim Panel Replacement (Extended Cab) (See: ).
5. Grasp the lower body rear corner trim panel and gently pull the panel away from the body to
release the fasteners. 6. Remove any fasteners that may have pulled away from the panel and
reinstall them to the back of the panel. 7. Slide the panel forward so the panel unhooks from
around the door frame. 8. Remove the lower body rear corner trim panel from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10188
1. Position the lower body rear corner trim panel so that the front edge hooks around the door
frame. 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel
by pushing firmly against the body to seat the panel fasteners. 4. Install the body rear trim panel.
Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: )Body Rear Trim Panel
Replacement (Regular
Cab) (See: )Body Rear Trim Panel Replacement (Extended Cab) (See: ).
5. Install the rear folding seat. Refer to Folding Seat Replacement (Extended Cab) (See:
Seats/Service and Repair/Folding Seat Replacement
(Extended Cab)).
6. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Extended Cab) (See:
Seats/Seat Back/Service and Repair/Rear Seat
Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab)
(See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)).
7. Install the rear door sill plates. Refer to Rear Side Door Sill Trim Plate Replacement (See: Scuff
Plate/Service and Repair).
Body Side Rear Lower Trim Panel Replacement (Regular Cab)
Body Side Rear Lower Trim Panel Replacement (Regular Cab)
Removal Procedure
1. Remove the rear door sill plates. Refer to Rear Side Door Sill Trim Plate Replacement (See:
Scuff Plate/Service and Repair). 2. Remove the front seat. Refer to Front Seat Replacement Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). 3. Remove the body
rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: )Body Rear Trim
Panel Replacement (Regular
Cab) (See: )Body Rear Trim Panel Replacement (Extended Cab) (See: ).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10189
4. Grasp the lower body rear corner trim panel and gently pull the panel away from the body to
release the fasteners. 5. Remove any fasteners that may have pulled away from the panel and
reinstall them to the back of the panel. 6. Slide the panel forward so the panel unhooks from
around the door frame. 7. Remove the lower body rear corner trim panel from the vehicle.
Installation Procedure
1. Position the lower body rear corner trim panel so that the front edge hooks around the door
frame. 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel
by pushing firmly against the body to seat the panel fasteners. 4. Install the body rear trim panel.
Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: )Body Rear Trim Panel
Replacement (Regular
Cab) (See: )Body Rear Trim Panel Replacement (Extended Cab) (See: ).
5. Remove the front seat. Refer to Front Seat Replacement - Bucket (See: Seats/Service and
Repair/Front Seat Replacement - Bucket). 6. Install the rear door sill plates. Refer to Rear Side
Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair).
Body Side Upper Trim Panel Replacement (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10190
Body Side Upper Trim Panel Replacement (Crew Cab)
Removal Procedure
1. Remove the lower body rear corner trim panel (1). Refer to Body Side Rear Lower Trim Panel
Replacement (Regular Cab) (See: )Body Side
Rear Lower Trim Panel Replacement (Crew Cab) (See: )Body Side Rear Lower Trim Panel
Replacement (Extended Cab) (See: ).
2. Remove the upper anchor bolt for the rear seat belt. Refer to Rear Seat Belt Replacement (See:
Restraint Systems/Seat Belt Systems/Seat
Belt/Service and Repair/Rear Seat Belt Replacement).
3. Remove the seat belt adjuster knob. 4. Remove the trim plate (2). 5. Remove the bolt securing
the roof rail air bag tether (4). 6. Grasp the top of the upper body rear corner trim panel (3) and
gently pull the panel away from the body to release the fasteners. 7. Remove any fasteners that
may have pulled away from the panel and reinstall them to the back of the panel. 8. Remove the
upper body rear corner trim panel from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10191
1. Position the upper body rear corner trim panel (3). 2. Ensure that the panel fasteners are aligned
with the holes in the body. 3. Install the upper body rear corner trim panel (3) by pushing firmly
against the body to seat the panel fasteners.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the bolt securing the roof rail air bag tether (4). Ensure that the tether strap is not twisted.
Tighten the roof rail air bag tether bolt to 9 Nm
(79 lb in).
5. Install the trim plate (2). 6. Install the seat belt adjuster knob. 7. Install the upper anchor bolt for
the front seat belt. Refer to Rear Seat Belt Replacement (See: Restraint Systems/Seat Belt
Systems/Seat
Belt/Service and Repair/Rear Seat Belt Replacement).
8. Install the lower body rear corner trim panel (1). Refer to Body Side Rear Lower Trim Panel
Replacement (Regular Cab) (See: )Body Side Rear
Lower Trim Panel Replacement (Crew Cab) (See: )Body Side Rear Lower Trim Panel
Replacement (Extended Cab) (See: ).
Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab)
Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab)
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10192
1. Remove the lower body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel
Replacement (Regular Cab) (See: )Body Side Rear
Lower Trim Panel Replacement (Crew Cab) (See: )Body Side Rear Lower Trim Panel
Replacement (Extended Cab) (See: ).
2. Remove the upper anchor bolt for the rear seat belt. Refer to Rear Seat Belt Replacement (See:
Restraint Systems/Seat Belt Systems/Seat
Belt/Service and Repair/Rear Seat Belt Replacement).
3. Remove the seat belt adjuster knob. 4. Remove the trim plate. 5. Grasp the top of the upper
body rear corner trim panel and gently pull the panel away from the body to release the fasteners.
6. Remove any fasteners that may have pulled away from the panel and reinstall them to the back
of the panel. 7. Remove the upper body rear corner trim panel from the vehicle.
Installation Procedure
1. Position the upper body rear corner trim panel. 2. Ensure that the panel fasteners are aligned
with the holes in the body. 3. Install the upper body rear corner trim panel by pushing firmly against
the body to seat the panel fasteners. 4. Install the trim plate. 5. Install the seat belt adjuster knob.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10193
6. Install the upper anchor bolt for the front seat belt. Refer to Rear Seat Belt Replacement (See:
Restraint Systems/Seat Belt Systems/Seat
Belt/Service and Repair/Rear Seat Belt Replacement).
7. Install the lower body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel
Replacement (Regular Cab) (See: )Body Side Rear
Lower Trim Panel Replacement (Crew Cab) (See: )Body Side Rear Lower Trim Panel
Replacement (Extended Cab) (See: ).
Center Pillar Lower Trim Panel Replacement
Center Pillar Lower Trim Panel Replacement
Removal Procedure
1. Grasp the lower center pillar trim panel and gently pull the panel away from the body to release
the fasteners. 2. Remove any fasteners that may have pulled away from the panel and reinstall
them to the back of the panel. 3. Slide the panel forward so the panel unhooks from around the
front door frame. 4. Remove the lower center pillar trim panel from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10194
1. Position the lower center pillar trim panel so that the front edge hooks around the front door
frame. 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel
by pushing firmly against the body to seat the panel fasteners.
Center Pillar Upper Trim Panel Replacement
Center Pillar Upper Trim Panel Replacement
Removal Procedure
1. Remove the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement
(See: ). 2. Remove the upper anchor bolt for the front seat belt. Refer to Front Seat Belt
Replacement (Crew Cab) (See: Restraint Systems/Seat Belt
Systems/Seat Belt/Service and Repair/Front Seat Belt Replacement (Crew Cab))Front Seat Belt
Replacement (Regular and Extended Cab) (See: Restraint Systems/Seat Belt Systems/Seat
Belt/Service and Repair/Front Seat Belt Replacement (Regular and Extended Cab)).
3. Remove the seat belt adjuster knob.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10195
4. Grasp the top of the upper center pillar trim panel and gently pull the panel away from the body
to release the fasteners. 5. Remove any fasteners that may have pulled away from the panel and
reinstall them to the back of the panel. 6. Remove the upper center pillar trim panel from the
vehicle.
Installation Procedure
1. Position the upper center pillar trim panel. 2. Ensure that the panel fasteners are aligned with the
holes in the body. 3. Install the panel by pushing firmly against the body to seat the panel
fasteners. 4. Install the seat belt adjuster knob. 5. Install the upper anchor bolt for the front seat
belt. Refer to Front Seat Belt Replacement (Crew Cab) (See: Restraint Systems/Seat Belt
Systems/Seat Belt/Service and Repair/Front Seat Belt Replacement (Crew Cab))Front Seat Belt
Replacement (Regular and Extended Cab) (See: Restraint Systems/Seat Belt Systems/Seat
Belt/Service and Repair/Front Seat Belt Replacement (Regular and Extended Cab)).
6. Install the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement
(See: ).
Jack Stowage Cover Replacement
Jack Stowage Cover Replacement
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10196
1. Remove the screw securing the jack cover to the jack stowage bracket. 2. Remove the jack
cover by lifting up to release the tab from behind the jack stowage bracket.
Installation Procedure
1. Position the jack cover over the jack stowage bracket ensuring that the tab on the rear of the
cover hooks behind the top of the jack stowage
bracket.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the screw securing the jack cover to the jack stowage bracket. Tighten the jack cover
screw until fully seated, tight, but not stripped.
Rear Side Door Latch Striker Cover Replacement (Extended Cab)
Rear Side Door Latch Striker Cover Replacement (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10197
Removal Procedure
1. Open the rear door.
2. Grasp the weatherstrip and gently pull the weatherstrip away from the door opening near the trim
cover.
3. Remove the push-pin securing the cover to the vehicle. 4. Remove the trim cover.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10198
1. Position the trim cover (3) to the vehicle ensuring that the retaining tabs (2) are properly
engaged to the headliner (1).
2. Install the push-pin securing the trim cover to the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10199
3. Install the weatherstrip by pushing it firmly back into place. 4. Close the rear door.
Windshield Pillar Garnish Molding Replacement
Windshield Pillar Garnish Molding Replacement
Removal Procedure
1. Remove the bolt cover (1) using a flat-bladed plastic tool. 2. Remove the windshield garnish
molding bolt (3) securing the molding to the pillar. 3. Remove the windshield garnish molding by
pulling the molding away from the pillar.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10200
1. Position the windshield garnish molding on the pillar. 2. Install the molding by firmly pressing the
molding against the pillar to seat the fasteners (2).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the windshield garnish molding bolt (3). Tighten the bolt to 9 Nm (79 lb in).
4. Install the bolt cover (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage
Compartment Latch > Component Information > Technical Service Bulletins > Customer Interest for Utility Storage
Compartment Latch: > 09-08-110-018A > Oct > 10 > Interior - Rear Storage Area Latch Separated/Broken
Utility Storage Compartment Latch: Customer Interest Interior - Rear Storage Area Latch
Separated/Broken
TECHNICAL
Bulletin No.: 09-08-110-018A
Date: October 21, 2010
Subject: Rear Storage Compartment Latch Separated or Broken (Replace Latch)
Models:
2006-2009 Chevrolet Colorado 2006-2009 GMC Canyon
Supercede: This bulletin is being revised to remove the Warranty Parts Center Parts Request Form
and add Parts Information. Please discard Corporate Bulletin Number 09-08-110-018 (Section 08 Body and Accessories).
Condition
Some customers may comment that one or both of the rear storage compartment latches have
separated or broken from the housing.
Cause
This condition may be caused by the storage compartment latch rivets pulling out of the housing,
which may also cause the latch to break.
Correction
Replace the storage compartment latch with a revised latch using the procedure below.
Important Use caution when drilling out the rivets. Do not enlarge the holes in the compartment lid.
1. Remove any remaining broken latch components (1) from the storage compartment. Drill out the
rivets from remaining broken parts if required.
2. Inspect the storage compartment lid for damage or cracks around the latch mounting surface (1).
Replace the storage compartment if damage is
evident. Refer to Rear Storage Compartment Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage
Compartment Latch > Component Information > Technical Service Bulletins > Customer Interest for Utility Storage
Compartment Latch: > 09-08-110-018A > Oct > 10 > Interior - Rear Storage Area Latch Separated/Broken > Page 10210
Important Use only a 1/8 in diameter by 5/8 in long pop rivet with a 1/8 in inside diameter by 3/8 in
outside diameter back-up washer to install the latch.
3. Install the revised latch using a 1/8 in diameter by 5/8 in long pop rivet (1).
Install the 1/8 in inside diameter by 3/8 in outside diameter back-up washer (1) when installing the
rivet to ensure the rivet does not pull through.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage
Compartment Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Utility
Storage Compartment Latch: > 09-08-110-018A > Oct > 10 > Interior - Rear Storage Area Latch Separated/Broken
Utility Storage Compartment Latch: All Technical Service Bulletins Interior - Rear Storage Area
Latch Separated/Broken
TECHNICAL
Bulletin No.: 09-08-110-018A
Date: October 21, 2010
Subject: Rear Storage Compartment Latch Separated or Broken (Replace Latch)
Models:
2006-2009 Chevrolet Colorado 2006-2009 GMC Canyon
Supercede: This bulletin is being revised to remove the Warranty Parts Center Parts Request Form
and add Parts Information. Please discard Corporate Bulletin Number 09-08-110-018 (Section 08 Body and Accessories).
Condition
Some customers may comment that one or both of the rear storage compartment latches have
separated or broken from the housing.
Cause
This condition may be caused by the storage compartment latch rivets pulling out of the housing,
which may also cause the latch to break.
Correction
Replace the storage compartment latch with a revised latch using the procedure below.
Important Use caution when drilling out the rivets. Do not enlarge the holes in the compartment lid.
1. Remove any remaining broken latch components (1) from the storage compartment. Drill out the
rivets from remaining broken parts if required.
2. Inspect the storage compartment lid for damage or cracks around the latch mounting surface (1).
Replace the storage compartment if damage is
evident. Refer to Rear Storage Compartment Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage
Compartment Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Utility
Storage Compartment Latch: > 09-08-110-018A > Oct > 10 > Interior - Rear Storage Area Latch Separated/Broken > Page
10216
Important Use only a 1/8 in diameter by 5/8 in long pop rivet with a 1/8 in inside diameter by 3/8 in
outside diameter back-up washer to install the latch.
3. Install the revised latch using a 1/8 in diameter by 5/8 in long pop rivet (1).
Install the 1/8 in inside diameter by 3/8 in outside diameter back-up washer (1) when installing the
rivet to ensure the rivet does not pull through.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Jack > Component Information > Service and Repair
Jack: Service and Repair
Jack and Tool Stowage Container Bracket Replacement
Removal Procedure
1. Remove the jack stowage cover. Refer to Jack Stowage Cover Replacement (See: Interior
Moulding / Trim/Trim Panel/Service and Repair).
2. Remove the jack from the stowage bracket by turning the jack handle to loosen the jack. 3.
Remove the 2 bolts securing the jack stowage bracket to the vehicle.
Installation Procedure
1. Position the jack stowage bracket on the floor stud in the vehicle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Jack > Component Information > Service and Repair > Page 10220
2. Install the 2 bolts securing the jack stowage bracket to the vehicle. Tighten the jack stowage
bracket bolts to 9 Nm (79 lb in).
3. Install the jack in the stowage bracket by positioning the jack on the 2 studs then turning the jack
handle to tighten the jack in the bracket. 4. Install the jack stowage cover. Refer to Jack Stowage
Cover Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair > Door Lock Cylinder Replacement
Door Lock Cylinder: Service and Repair Door Lock Cylinder Replacement
Front Side Door Lock Cylinder Replacement
Removal Procedure
1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See:
Doors, Hood and Trunk/Doors/Front Door/Front
Door Panel/Service and Repair).
2. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement
(See: Doors, Hood and Trunk/Doors/Front
Door/Front Door Panel/Service and Repair).
3. Remove the front outside door handle. Refer to Front Side Door Outside Handle Replacement
(See: Doors, Hood and Trunk/Doors/Front
Door/Front Door Handle/Front Door Exterior Handle/Service and Repair).
4. Remove the bolts retaining the lock cylinder to the front outside door handle. 5. Remove the lock
cylinder from the door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair > Door Lock Cylinder Replacement > Page 10227
1. Install the lock cylinder to the front outside door handle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the lock cylinder to the outside door handle.
Tighten the lock cylinder bolts to 9 Nm (80 lb in).
3. Install the front outside door handle. Refer to Front Side Door Outside Handle Replacement
(See: Doors, Hood and Trunk/Doors/Front
Door/Front Door Handle/Front Door Exterior Handle/Service and Repair).
4. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement
(See: Doors, Hood and Trunk/Doors/Front
Door/Front Door Panel/Service and Repair).
5. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Doors,
Hood and Trunk/Doors/Front Door/Front Door
Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair > Door Lock Cylinder Replacement > Page 10228
Door Lock Cylinder: Service and Repair Rear Door Lock Cylinder Replacement
Endgate Lock Cylinder Replacement
Removal Procedure
1. Remove the endgate cover. Refer to Pickup Box Endgate Latch Cover Replacement (). 2.
Disconnect the clip (1) retaining the lock rod to the lock cylinder. 3. Remove the lock rod from the
retaining clip (1). 4. Remove the bolt retaining the lock cylinder to the endgate handle. 5. Remove
the lock cylinder from the endgate handle.
Installation Procedure
1. Code the new lock cylinder. Refer to Key and Lock Cylinder Coding (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair > Door Lock Cylinder Replacement > Page 10229
2. Install the lock cylinder to the endgate handle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the bolt retaining the lock cylinder to the endgate handle.
Tighten the lock cylinder bolt to 9 Nm (80 lb in).
4. Install the lock rod to the retaining clip (1). 5. Connect the clip (1) retaining the lock rod to the
lock cylinder. 6. Install the endgate cover. Refer to Pickup Box Endgate Latch Cover Replacement
().
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins >
Locks - Key Code Security Rules and Information
Key: Technical Service Bulletins Locks - Key Code Security Rules and Information
INFORMATION
Bulletin No.: 10-00-89-010
Date: May 27, 2010
Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada
Only)
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior
Saturn and Saab 2002 and Prior Isuzu
Attention:
This bulletin has been created to address potential issues and questions regarding KeyCode
security. This bulletin should be read by all parties involved in KeyCode activity, including dealer
operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin
should be printed and maintained in the parts department for use as a reference.
Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009.
Where Are Key Codes Located?
General Motors provides access to KeyCodes through three sources when a vehicle is delivered to
a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a
small white bar coded tag sent with most new vehicles that also has the key code printed on it.
Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed
on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code
Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers.
The third source for Key codes is through the GM KeyCode Look-Up feature within the
OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model
years from the current model year.
When a vehicle is received by the dealership, care should be taken to safeguard the original
vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have
access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been
completed, the KeyCode information belongs to the customer and General Motors.
Tip
Only the original invoice contains key code information, a re-printed invoice does not.
GM KeyCode Look-Up Application for GM of Canada Dealers
All dealers should review the General Motors of Canada KeyCode Look-Up Policies and
Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates &
keys").
Please note that the KeyCode Access site is restricted. Only authorized users should be using this
application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently
goes back 17 years from current model year.
Important notes about security:
- Users may not access the system from multiple computers simultaneously.
- Users may only request one KeyCode at a time.
- KeyCode information will only be available on the screen for 2 minutes.
- Each user is personally responsible for maintaining and protecting their password.
- Never share your password with others.
- User Id's are suspended after 6 consecutive failed attempts.
- User Id's are disabled if not used for 90 days.
- Processes must be in place for regular dealership reviews.
- The Parts Manager (or assigned management) must have processes in place for employee
termination or life change events. Upon termination individuals access must be turned off
immediately and access should be re-evaluated upon any position changes within the dealership.
- If you think your password or ID security has been breached, contact Dealer Systems Support at
1-800-265-0573.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins >
Locks - Key Code Security Rules and Information > Page 10234
Each user will be required to accept the following agreement each time the KeyCode application is
used.
Key Code User Agreement
- Key codes are proprietary information belonging to General Motors Corporation and to the vehicle
owner.
- Unauthorized access to, or use of, key code information is unlawful and may subject the user to
criminal and civil penalties.
- This information should be treated as strictly confidential and should not be disclosed to anyone
unless authorized.
I will ensure that the following information is obtained prior to releasing any Key Code information:
1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership.
Registration should have normal markings from the Province that issued the registration and
possibly the
receipt for payment recorded as well.
Important
- GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving
out key codes.
- When the ownership of the vehicle is in doubt, dealership personnel should not provide the
information.
Key code requests should never be received via a fax or the internet and key codes should never
be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the
expected manner that dealers will use to release a key code or as otherwise stipulated in this
bulletin or other materials.
- Key codes should NEVER be sent via a fax or the internet.
- Each Dealership should create a permanent file to document all KeyCode Look Up transactions.
Requests should be filed by VIN and in each folder retain copies of the following:
- Government issued picture ID (Drivers License)
- Registration or other proof of ownership.
- Copy of the paid customer receipt which has the name of the employee who cut and sold the key
to the customer.
- Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up
to either GM or law enforcement officials.
- Dealership Management has the ability to review all KeyCode Look-Up transactions.
- Dealership KeyCode documentation must be retained for two years.
Frequently Asked Questions (FAQs) for GM of Canada Dealers
How do I request a KeyCode for customer owned vehicle that is not registered?
Scrapped, salvaged or stored vehicles that do not have a current registration should still have the
ownership verified by requesting the vehicle title, current insurance policy and / or current lien
holder information from the customers financing source. If you cannot determine if the customer is
the owner of the vehicle, do not provide the key code information. In these cases, a short
description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on
file. Any clarifying explanation should be entered into the comments field.
How do I document a KeyCode request for a vehicle that is being repossessed?
The repossessor must document ownership of the vehicle by providing a court ordered
repossession order and lien-holder documents prior to providing key code information. Copies of
the repossessors Drivers License and a business card should be retained by the dealership for
documentation.
What do I do if the registration information is locked in the vehicle?
Every effort should be made to obtain complete information for each request. Each Dealership will
have to decide on a case by case basis if enough information is available to verify the customer's
ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and
or current lien information from the customers financing source. Dealership Management must be
involved in any request without complete information. If you cannot determine if the customer is the
owner of the vehicle, do not provide the key code information.
Can I get a print out of the information on the screen?
It is important to note that the Key Code Look Up Search Results contain sensitive and/or
proprietary information. For this reason GM recommends against printing it. If the Search Results
must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper
or illegal use.
Who in the dealership has access to the KeyCode application?
Dealership Parts Manager (or assigned management) will determine, and control, who is
authorized to access the KeyCode Look Up application. However, we anticipate that dealership
parts and service management will be the primary users of the application. The KeyCode Look Up
application automatically tracks each user activity session. Information tracked by the system
includes: User name, User ID, all other entered data and the date/time of access.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins >
Locks - Key Code Security Rules and Information > Page 10235
What if I input the VIN incorrectly?
If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN
or that the VIN has been entered incorrectly) the system will return an error message.
If I am an authorized user for the KeyCode application, can I access the application from home?
Yes.
What if I suspect key code misuse?
Your dealership should communicate the proper procedures for requesting key codes. Any
suspicious activity either within the dealership or externally should be reported to Dealer Systems
Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
Whose key codes can I access through the system?
At this time the following Canadian vehicle codes are available through the system: Chevrolet,
Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu
(up to 2002 model year) for a maximum of 17 model years.
What should I do if I enter a valid VIN and the system does not produce any key code information?
Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This
may be the result of new vehicle information not yet available. In addition, older vehicle information
may have been sent to an archive status. If you do not receive a key code returned for valid VIN,
you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
How do I access KeyCodes if the KeyCode Look-up system is down?
If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling
dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at
1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have
the customer contact Roadside assistance, OnStar if subscribed, or 911.
What should I do if the KeyCode from the look-up system does not work on the vehicle?
On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In
cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting
equipment that the key has been cut correctly. If the key has been cut correctly you may be able to
verify the proper KeyCode was given through the original selling dealer. When unable to verify the
KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at
1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock
cylinder may have been changed. In these situations following the proper SI document for recoding
a key or replacing the lock cylinder may be necessary.
How long do I have to keep KeyCode Records?
Dealership KeyCode documentation must be retained for two years.
Can I get a KeyCode changed in the Look-Up system?
Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed.
Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
What information do I need before I can provide a driver of a company fleet vehicle Keys or
KeyCode information?
The dealership should have a copy of the individual's driver's license, proof of employment and
registration. If there is any question as to the customer's employment by the fleet company, the
dealer should attempt to contact the fleet company for verification. If there is not enough
information to determine ownership and employment, this information should not be provided.
How do I document a request from an Independent Repair facility for a KeyCode or Key?
The independent must provide a copy of their driver's license, proof of employment and signed
copy of the repair order for that repair facility. The repair order must include customer's name,
address, VIN, city, province and license plate number. Copies of this information must be included
in your dealer KeyCode file.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins >
Locks - Key Code Security Rules and Information > Page 10236
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component
Information > Service and Repair
Keyless Entry Transmitter: Service and Repair
Transmitter Programming
Important: Up to 4 transmitters can be programmed. Do not operate or program the transmitters in
the vicinity of other vehicles that are in the keyless entry program mode. This prevents the
programming of the transmitters to the incorrect vehicle. The order in which the transmitters are
programmed is important. The first transmitter programmed will be transmitter #1, and the second
transmitter programmed will be transmitter #2. Use care to program the transmitters correctly.
Important: All key fobs must be programmed each time any one fob is programmed. The scan tool
must stay connected until all of the transmitters are programmed.
1. Install a scan tool and navigate to the BCM Module Setup menu. 2. Select Program Key Fobs. 3.
Follow the scan tool on-screen directions. 4. When the programming operations have completed,
operate the transmitter functions to verify correct system operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Door Component Views
Power Door Lock Actuator: Locations Door Component Views
Door Component Views
Driver Door Components
1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker
- Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch
(DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF)
Front Passenger Door Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Door Component Views > Page 10246
1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door
Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210
Left Rear Door Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Door Component Views > Page 10247
1 - Speaker - Left Rear 2 - Window Switch - Left Rear (A31) 3 - X316 4 - Window Motor - Left Rear
(A31) 5 - Door Lock Actuator - Left Rear (AU3)
Right Rear Door Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Door Component Views > Page 10248
1 - Window Switch - Right Rear (A31) 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right
Rear (AU3) 4 - Window Motor - Right Rear (A31) 5 - X317
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Door Component Views > Page 10249
Power Door Lock Actuator: Locations Harness Routing Views
Harness Routing Views
Driver Door Harness Routing
1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside
Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body
Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver
Front Passenger Door Harness Routing
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Door Component Views > Page 10250
1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front
Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body
Harness) 9 - X210 (Body Harness to Front Passenger Door Harness)
Left Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Door Component Views > Page 10251
1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness
to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear
Right Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Door Component Views > Page 10252
1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock
Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door
Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Page 10253
Power Door Lock Actuator: Diagrams
Component Connector End Views
Door Lock Actuator - Driver (AU3)
Door Lock Actuator - Passenger (AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Page 10254
Door Lock Actuator - Left Rear (Crew Cab with AU3)
Door Lock Actuator - Right Rear (Crew Cab with AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Page 10255
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations > Door Component Views
Power Door Lock Switch: Locations Door Component Views
Door Component Views
Driver Door Components
1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker
- Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch
(DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF)
Front Passenger Door Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations > Door Component Views > Page 10260
1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door
Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations > Door Component Views > Page 10261
Power Door Lock Switch: Locations Harness Routing Views
Harness Routing Views
Driver Door Harness Routing
1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside
Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body
Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver
Front Passenger Door Harness Routing
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations > Door Component Views > Page 10262
1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front
Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body
Harness) 9 - X210 (Body Harness to Front Passenger Door Harness)
Right Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations > Door Component Views > Page 10263
1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock
Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door
Harness)
Left Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations > Door Component Views > Page 10264
1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness
to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations > Page 10265
Power Door Lock Switch: Diagrams
Component Connector End Views
Door Lock/Window Switch - Driver X1 (A31/AU3)
Door Lock/Window Switch - Driver X2 (A31/AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations > Page 10266
Door Lock/Window Switch - Passenger (A31/AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations > Page 10267
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Service and Repair > Door Lock Switch Replacement - Driver Door
Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Driver Door
Door Lock Switch Replacement - Driver Door
Removal Procedure
1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the front
of the switch plate up to disengage clip. 3. Remove the switch plate out of the door trim panel
opening.
4. Disconnect the electrical connectors (3, 4) from the switches (2, 5). 5. Remove the switch plate
assembly (1) from the vehicle. 6. If replacing only the switches, remove the switches from the plate.
7. If replacing only the switch plate, retain the switches for transfer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Service and Repair > Door Lock Switch Replacement - Driver Door > Page 10270
Installation Procedure
1. Install the switches (2, 5) to the switch plate (1). 2. Connect the electrical connectors (3, 4) to the
switches (2, 5).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the switch plate assembly to the door trim panel with the 2 screws.
Tighten the front door switch plate screws to 2 Nm (18 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Service and Repair > Door Lock Switch Replacement - Driver Door > Page 10271
Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Passenger Front
Door Lock Switch Replacement - Passenger Front
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical
Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time
Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time
INFORMATION
Bulletin No.: 08-08-64-011A
Date: February 25, 2010
Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance
Models:
2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories).
Defrosting Time/Performance Concern
The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM
vehicles is slower to defrost than the passenger side outside rearview mirror.
This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as
the traditional glass on the passenger side mirror. The heating elements for the mirrors on both
sides draw the same wattage, therefore the driver's side mirror will take approximately twice as
long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a
customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function
based upon this information prior to replacing the mirror.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and
Repair
Power Mirror Motor: Service and Repair
Outside Rearview Mirror Motor Replacement
Removal Procedure
1. Remove the mirror glass. Refer to Outside Rearview Mirror Glass Replacement (See: Service
and Repair/Outside Rearview Mirror Glass
Replacement).
2. Remove the screws retaining the mirror motor to the mirror housing.
3. Rotate the bottom of the mirror motor upward to disengage the mirror motor (1) from the mirror
housing retainers (2). 4. Disconnect the mirror motor electrical connectors. 5. Remove the mirror
motor from the mirror housing.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and
Repair > Page 10280
1. Position the mirror motor to the mirror housing. 2. Connect the mirror motor electrical
connectors. 3. Install the mirror motor to the mirror housing by engaging the mirror motor (1) to the
mirror housing retainers (2) and rotating the motor
downward.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the screws retaining the mirror motor to the mirror housing.
Tighten the mirror motor screws to 9 Nm (80 lb in).
5. Install the mirror glass. Refer to Outside Rearview Mirror Glass Replacement (See: Service and
Repair/Outside Rearview Mirror Glass
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations >
Door Component Views
Power Mirror Switch: Locations Door Component Views
Door Component Views
Driver Door Components
1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker
- Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch
(DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations >
Door Component Views > Page 10285
Power Mirror Switch: Locations Harness Routing Views
Harness Routing Views
Driver Door Harness Routing
1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside
Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body
Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations >
Page 10286
Power Mirror Switch: Diagrams
Component Connector End Views
Outside Rearview Mirror Switch (DE6)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint
Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint
TECHNICAL
Bulletin No.: 05-08-51-008C
Date: June 22, 2009
Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust)
Models:
1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-08-51-008B (Section 08 - Body and Accessories).
Condition
Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust.
Cause
Rail dust comes from tiny iron particles produced from the friction between train wheels and the
tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the
vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material
can lay on top of, or become embedded in, the paint surface.
Correction
Because the severity of the condition varies, proper diagnosis of the damage is critical to the
success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick
up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials
recommended to repair rail dust or iron dust:
1. GEL TYPE OXALIC ACID:
- Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel
consistency.
2. CLAY TYPE NON-ACID BASED:
- Requires surface lubricant during use. - Has different grades available.
Caution
Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down
the iron particles embedded in the finish. When working with rail dust remover, use the necessary
safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions
closely because it may require special handling and disposal.
If, upon inspection, some particles are still present, the various chemical manufacturer's processes
can be repeated.
After the removal process, small pits may remain in the clearcoat and can be corrected, in most
cases, with a finesse/polish operation.
Procedure
1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during
the removal process. DO NOT PERFORM THE
REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY
PANELS.
2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a
wax and grease remover. 3. Perform the removal process according to the chemical
manufacturer's directions.
Once the damage has been repaired, the final step involves a polishing process.
Rail Dust Remover Manufacturers
Use the chemical manufacturers listed below, or equivalent:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page
10296
Auto Magic(R) or Clay Magic(R) products available from:
Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or
(214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com
[email protected]
E038 Fallout Gel or E038E Liquid Fallout Remover II available from:
Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll
Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com
[email protected] *We
believe these sources and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from these firms or for any such items which may be available from
other sources.
If rail dust remover is not available in your area, call one of the numbers listed above for a
distributor near your location.
Warranty Information (excluding Saab U.S. Models)
Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information
regarding warranty coverage for this condition.
Important In certain cases where the vehicle finish is severely damaged and the actual repair time
exceeds the published time, the additional time should be submitted in the "Other Labor Hours"
field.
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored
Spots in Paint
Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint
TECHNICAL
Bulletin No.: 05-08-51-008C
Date: June 22, 2009
Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust)
Models:
1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-08-51-008B (Section 08 - Body and Accessories).
Condition
Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust.
Cause
Rail dust comes from tiny iron particles produced from the friction between train wheels and the
tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the
vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material
can lay on top of, or become embedded in, the paint surface.
Correction
Because the severity of the condition varies, proper diagnosis of the damage is critical to the
success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick
up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials
recommended to repair rail dust or iron dust:
1. GEL TYPE OXALIC ACID:
- Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel
consistency.
2. CLAY TYPE NON-ACID BASED:
- Requires surface lubricant during use. - Has different grades available.
Caution
Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down
the iron particles embedded in the finish. When working with rail dust remover, use the necessary
safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions
closely because it may require special handling and disposal.
If, upon inspection, some particles are still present, the various chemical manufacturer's processes
can be repeated.
After the removal process, small pits may remain in the clearcoat and can be corrected, in most
cases, with a finesse/polish operation.
Procedure
1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during
the removal process. DO NOT PERFORM THE
REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY
PANELS.
2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a
wax and grease remover. 3. Perform the removal process according to the chemical
manufacturer's directions.
Once the damage has been repaired, the final step involves a polishing process.
Rail Dust Remover Manufacturers
Use the chemical manufacturers listed below, or equivalent:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored
Spots in Paint > Page 10302
Auto Magic(R) or Clay Magic(R) products available from:
Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or
(214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com
[email protected]
E038 Fallout Gel or E038E Liquid Fallout Remover II available from:
Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll
Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com
[email protected] *We
believe these sources and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from these firms or for any such items which may be available from
other sources.
If rail dust remover is not available in your area, call one of the numbers listed above for a
distributor near your location.
Warranty Information (excluding Saab U.S. Models)
Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information
regarding warranty coverage for this condition.
Important In certain cases where the vehicle finish is severely damaged and the actual repair time
exceeds the published time, the additional time should be submitted in the "Other Labor Hours"
field.
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Technical Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior
to Painting
Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting
INFORMATION
Bulletin No.: 08-08-51-002
Date: March 12, 2008
Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation
Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3
The purpose of this bulletin is to inform the technician that General Motors has made a change in
the primer it uses for TPO plastic for service parts. This new primer comes in several different
colors from five different suppliers. This change affects the cleaning process of the painting
operation. The new process is as follows.
1. Wash with soap and water.
2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your
paint supplier for product recommendations.
3. Scuff sand per your paint suppliers recommendations.
Note:
The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not
have any affect on this primer.
4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner).
All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You
may find other TPO parts with this primer. If the technician has a question as to the type of plastic
they are painting, inspect the back of the part for the plastic symbol (TPO).
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to
Painting
Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting
INFORMATION
Bulletin No.: 08-08-51-002
Date: March 12, 2008
Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation
Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3
The purpose of this bulletin is to inform the technician that General Motors has made a change in
the primer it uses for TPO plastic for service parts. This new primer comes in several different
colors from five different suppliers. This change affects the cleaning process of the painting
operation. The new process is as follows.
1. Wash with soap and water.
2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your
paint supplier for product recommendations.
3. Scuff sand per your paint suppliers recommendations.
Note:
The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not
have any affect on this primer.
4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner).
All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You
may find other TPO parts with this primer. If the technician has a question as to the type of plastic
they are painting, inspect the back of the part for the plastic symbol (TPO).
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > Page 10312
Paint: By Symptom
Technical Service Bulletin # 05-08-51-008C Date: 090622
Body - Bumps or Rust Colored Spots in Paint
TECHNICAL
Bulletin No.: 05-08-51-008C
Date: June 22, 2009
Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust)
Models:
1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-08-51-008B (Section 08 - Body and Accessories).
Condition
Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust.
Cause
Rail dust comes from tiny iron particles produced from the friction between train wheels and the
tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the
vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material
can lay on top of, or become embedded in, the paint surface.
Correction
Because the severity of the condition varies, proper diagnosis of the damage is critical to the
success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick
up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials
recommended to repair rail dust or iron dust:
1. GEL TYPE OXALIC ACID:
- Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel
consistency.
2. CLAY TYPE NON-ACID BASED:
- Requires surface lubricant during use. - Has different grades available.
Caution
Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down
the iron particles embedded in the finish. When working with rail dust remover, use the necessary
safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions
closely because it may require special handling and disposal.
If, upon inspection, some particles are still present, the various chemical manufacturer's processes
can be repeated.
After the removal process, small pits may remain in the clearcoat and can be corrected, in most
cases, with a finesse/polish operation.
Procedure
1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during
the removal process. DO NOT PERFORM THE
REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY
PANELS.
2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a
wax and grease remover. 3. Perform the removal process according to the chemical
manufacturer's directions.
Once the damage has been repaired, the final step involves a polishing process.
Rail Dust Remover Manufacturers
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > Page 10313
Use the chemical manufacturers listed below, or equivalent:
Auto Magic(R) or Clay Magic(R) products available from:
Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or
(214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com
[email protected]
E038 Fallout Gel or E038E Liquid Fallout Remover II available from:
Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll
Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com
[email protected] *We
believe these sources and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from these firms or for any such items which may be available from
other sources.
If rail dust remover is not available in your area, call one of the numbers listed above for a
distributor near your location.
Warranty Information (excluding Saab U.S. Models)
Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information
regarding warranty coverage for this condition.
Important In certain cases where the vehicle finish is severely damaged and the actual repair time
exceeds the published time, the additional time should be submitted in the "Other Labor Hours"
field.
Warranty Information (Saab U.S. Models)
Disclaimer
Technical Service Bulletin # 05-08-51-008C Date: 090622
Body - Bumps or Rust Colored Spots in Paint
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > Page 10314
TECHNICAL
Bulletin No.: 05-08-51-008C
Date: June 22, 2009
Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust)
Models:
1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-08-51-008B (Section 08 - Body and Accessories).
Condition
Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust.
Cause
Rail dust comes from tiny iron particles produced from the friction between train wheels and the
tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the
vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material
can lay on top of, or become embedded in, the paint surface.
Correction
Because the severity of the condition varies, proper diagnosis of the damage is critical to the
success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick
up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials
recommended to repair rail dust or iron dust:
1. GEL TYPE OXALIC ACID:
- Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel
consistency.
2. CLAY TYPE NON-ACID BASED:
- Requires surface lubricant during use. - Has different grades available.
Caution
Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down
the iron particles embedded in the finish. When working with rail dust remover, use the necessary
safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions
closely because it may require special handling and disposal.
If, upon inspection, some particles are still present, the various chemical manufacturer's processes
can be repeated.
After the removal process, small pits may remain in the clearcoat and can be corrected, in most
cases, with a finesse/polish operation.
Procedure
1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during
the removal process. DO NOT PERFORM THE
REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY
PANELS.
2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a
wax and grease remover. 3. Perform the removal process according to the chemical
manufacturer's directions.
Once the damage has been repaired, the final step involves a polishing process.
Rail Dust Remover Manufacturers
Use the chemical manufacturers listed below, or equivalent:
Auto Magic(R) or Clay Magic(R) products available from:
Auto Wax Company, Inc.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > Page 10315
1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax
(214) 634-1342 www.automagic.com
[email protected] E038 Fallout Gel or E038E
Liquid Fallout Remover II available from:
Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll
Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com
[email protected] *We
believe these sources and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from these firms or for any such items which may be available from
other sources.
If rail dust remover is not available in your area, call one of the numbers listed above for a
distributor near your location.
Warranty Information (excluding Saab U.S. Models)
Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information
regarding warranty coverage for this condition.
Important In certain cases where the vehicle finish is severely damaged and the actual repair time
exceeds the published time, the additional time should be submitted in the "Other Labor Hours"
field.
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service
Precautions > Brake Fluid Effects on Paint and Electrical Components Caution
Paint: Service Precautions Brake Fluid Effects on Paint and Electrical Components Caution
Brake Fluid Effects on Paint and Electrical Components Caution
Caution: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables.
Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any
brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any
brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to
wipe away the fluid.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service
Precautions > Brake Fluid Effects on Paint and Electrical Components Caution > Page 10318
Paint: Service Precautions Clearcoat/Ultraviolet Screeners Caution
Clearcoat/Ultraviolet Screeners Caution
Caution: Removing more than 0.5 mils of the clearcoat can result in early paint failure. The
clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove
the defect.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application
and ID > Basecoat/Clearcoat Paint Systems
Paint: Application and ID Basecoat/Clearcoat Paint Systems
Basecoat/Clearcoat Paint Systems
Warning
Exposure to isocyanates during paint preparation and application processes can cause severe
breathing problems. Read and follow all of the instructions from the manufacturers of painting
materials, equipment, and protective gear.
All paint finish repairs of rigid exterior surfaces must meet GM standards. Refer to the latest
revision of the GM Approved Refinish Materials book to identify the paint systems you may use that
have been engineered to meet GM standards. The GM Approved Refinish Materials book supplies
all approved products, including volatile organic compound (VOC) compliant regulations
recommended by the individual manufacturer, and detailed procedures for materials used in their
paint system.
The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench
website.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application
and ID > Basecoat/Clearcoat Paint Systems > Page 10321
Paint: Application and ID Paint Identification
Paint Identification
Warning
Exposure to isocyanates during paint preparation and application processes can cause severe
breathing problems. Read and follow all of the instructions from the manufacturers of painting
materials, equipment, and protective gear.
Note: Always refer to the GM Approved Refinish Materials book. This book identifies the paint
systems you may use.
The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench
website.
Use the service parts identification label to identify the type of paint technology, paint codes, trim
level, and any special order paint colors on the vehicle. Refer to Vehicle Certification, Tire Placard,
Anti-Theft, and Service Parts ID Label (See: Application and ID).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Locations
Seat Heater Control Module: Locations
Passenger Compartment/Roof Component Views
Under the Driver Seat Components
1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1)
5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver
Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver
Under the Passenger Seat Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Locations > Page 10326
1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor
(SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger
(KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1)
7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Locations > Page 10327
Seat Heater Control Module: Service and Repair
Front Seat Heater Control Module Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Locations
Sunroof / Moonroof Motor: Locations
Passenger Compartment/Roof Component Views
Front of the Headliner Components (CF5)
1 - Sunroof Switch X2 2 - Sunroof Opening 3 - G300 4 - Sunroof Motor 5 - Sunroof Switch 6 Sunroof Switch X1 7 - Sunroof Ground Lead
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Locations > Page 10333
Sunroof / Moonroof Motor: Diagrams
Component Connector End Views
Sunroof Motor (CF5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Locations > Page 10334
Sunroof / Moonroof Motor: Service and Repair
Power Sunroof Motor Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations
Sunroof / Moonroof Switch: Locations
Passenger Compartment/Roof Component Views
Front of the Headliner Components (CF5)
1 - Sunroof Switch X2 2 - Sunroof Opening 3 - G300 4 - Sunroof Motor 5 - Sunroof Switch 6 Sunroof Switch X1 7 - Sunroof Ground Lead
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 10338
Sunroof / Moonroof Switch: Diagrams
Component Connector End Views
Sunroof Switch (CF5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 10339
Sunroof / Moonroof Switch: Service and Repair
Sunroof Switch Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures
Sunroof / Moonroof Track: Procedures
Sunroof Track Timing/Synchronization
Important: An improperly timed window panel can affect sunroof functionality, water test results,
and windnoise. If a repair involves the removal of sunroof motor for any reason, it is recommended
that the window timing be reset.
1. To reset window timing, the motor must be removed. Refer to Power Sunroof Motor
Replacement (See: Sunroof / Moonroof Motor/Service and
Repair).
2. Open the sunroof window to the fully vented position. 3. Apply even pressure to the front of the
window to move it to the fully open position. 4. There is a hard stop at the rear of the full open
position, which will stop the left and right cables in an identical rearward position. 5. Once fully
open and timed, the motor may be reinstalled. 6. The motor is not timed to the position of the
window, as the motor will continuously run in either direction until the switch is deactivated. Once
the
motor is reinstalled, test sunroof for functionality. The left and right sides of the window should
move, and close, simultaneously. Both rear corners of the window should appear to be the same
height, in the relation to the upper frame when in the closed position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10344
Sunroof / Moonroof Track: Removal and Replacement
Sunroof Guide Replacement
Sunroof Guide Replacement
Removal Procedure
1. Open the sunshade to the full open position. 2. Remove the sunroof front trim cover. Refer to
Sunroof Front Trim Cover Replacement (See: Sunroof / Moonroof Interior Trim Panel/Service and
Repair).
3. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement (See: Sunroof /
Moonroof Motor/Service and Repair).
Note: Note the location of the bolts, size and color when removing, for proper installation.
4. Remove the screws from around the lower frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10345
Note: Place the sunroof module on a flat protective cover, face down.
5. Remove the sunroof module and window from the vehicle. 6. Remove the sunroof motor. Refer
to Power Sunroof Motor Replacement (See: Sunroof / Moonroof Motor/Service and Repair).
7. Remove the cam plate screws (1). 8. Remove the cam plate (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10346
9. Lift upward on the drive cables (2) to release the cam (3) from the upper frame.
10. Remove the left and right side drive cable tube covers (1) from the drive cable (2).
Two drive cable tube covers to each side.
11. Push the drive cables up into the upper frame, this will allow the window to open manually.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10347
Note: Place the sunroof module on a flat protective cover, face down.
12. The sunroof window must be in the full open position to do the following:
1. Unhook the wind deflector slide blocks (1) from each side. 2. Unhook the wind deflector tabs (2)
from the center of the upper frame. 3. Remove the wind deflector.
Note: Mark the left and right sides of the guides in respect to the frame. This will assist in the
alignment of the window to the module later.
Note the location of the bolts, size and color when removing, for proper installation.
13. Remove the two screws (1) on each side of the guides (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10348
Note: Place the sunroof module on a flat protective cover, face down. It is necessary to slide the
guides about 1 cm (1 3/8 in) rearward to release the upper frame.
14. Rotate the upper frame back and fourth. Pushing forward on the upper frame until it is over the
guides.
15. Remove the upper frame (2) from the window and guides (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10349
16. Remove the guides (1) from the drive cables (4) and slides (3).
Installation Procedure
1. Install the guides (1) to the drive cables (4) and slides (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10350
2. Install the upper frame (2) to the window and guides (1).
Note: Place the sunroof module on a flat protective cover, face down. Rotate the upper frame back
and fourth until it is over the guides. Refer to the marked positions on the guides in respect to the
frame.
3. Place the guides about 1 cm (1 3/8 in) rearward to reinstall the upper frame. 4. Pull rearward on
the upper frame until the screws holes align with the guide holes.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10351
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: Using the marks on the left and right sides of the guides to reinstall the window to the module
for alignment.
5. Install the two screws (1) to each side of the guides (2).
Install the bolts, size and color to the proper location.
Tighten the screw to 3 Nm (27 lb in).
Note: Place the sunroof module on a flat protective cover, face down.
6. The sunroof window must be in the full open position to do the following:
1. Install the wind deflector. 2. Hook the wind deflector slide blocks (1) to each side. 3. Hook the
wind deflector tabs (2) to the center of the upper frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10352
7. Install the left and right side drive cable tube covers (1) to the cable (2).
Two drive cable tube covers to each side.
8. Pull the drive cables down through the guides and around the upper frame, this will allow the
window to be closed manually.
9. Install the drive cables (2) with cam (3).
Ensure that the chamfered edge of the gear is directed upward.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10353
10. Install the cam plate (2). 11. Install the cam plate screws (1).
Tighten the screw to 3 Nm (27 lb in).
12. Install the sunroof module to the vehicle.
13. Install the lower frame to the sunroof module. 14. Tighten the lower frame to the sunroof
module screws.
Tighten the screw to 3 Nm (27 lb in).
15. Install the sunroof motor. Refer to Power Sunroof Motor Replacement (See: Sunroof / Moonroof
Motor/Service and Repair). 16. Install the sunroof front trim cover. Refer to Sunroof Front Trim
Cover Replacement (See: Sunroof / Moonroof Interior Trim Panel/Service and
Repair).
17. Verify the operations of the sunroof window.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10354
Sunroof Sliding Block Guide Replacement
Sunroof Sliding Block Guide Replacement
Removal Procedure
1. Open the sunshade to the full open position. 2. Remove the sunroof module upper frame. Refer
to Sunroof Frame Replacement - Upper (See: Sunroof / Moonroof Frame/Service and
Repair/Sunroof Frame Replacement - Upper).
3. Remove the guides (1) from the sliders (2).
4. Remove the drive cables and sliders (1) from the guides.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10355
5. Remove the lever (1) by rotating it forward and slide it together with the locker slider forward.
6. Remove the lever carefully by using a flat-bladed tool between the track and the levers.
The track is not serviceable. If damaged replace the sunroof window.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10356
7. Remove the front end of the locker slider to the outside and slide it forward.
8. Apply a light coat of lubricant (1) to the following parts:
* The guides
* The curve of the driving slider
* The lever
* The locker sliders
* The track is not serviceable. If damaged replace the sunroof window. It bonded to the sunroof
window panel.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10357
1. Place the locker slide, with the front to the outside, and slide it rearward.
2. Slide the locker slider forward. 3. Push the pin (1) of the lever (2) carefully through the track (3)
in the locker slide.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10358
4. Slide the lever together with the locker slide rearward, and rotate the lever rearward.
5. Mount the driving slide (1) to the lever and the front tumbler.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10359
Important: Do Not force the guides to the sliders. Use care.
6. Position the front tumbler and the driving slide in-line with each other. 7. Slide the guide carefully
over the front tumbler and driving slider extends 4.5 cm (2 in) out of the guide.
8. Mount the drive cable on the driving slide. 9. Rotate the drive cable, so that the points of the oval
cable end fit into the guides.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Procedures > Page 10360
10. Slide the guides rearwards until the end of the driving slide is 1 cm (3/8 in) within the guide. 11.
Install the sunroof module upper frame. Refer to Sunroof Frame Replacement - Upper (See:
Sunroof / Moonroof Frame/Service and
Repair/Sunroof Frame Replacement - Upper).
12. Verify the operation of the sunroof. 13. Close the sunshade.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Windguard > Component Information > Service and Repair
Sunroof / Moonroof Windguard: Service and Repair
Sunroof Air Deflector Replacement
Removal Procedure
1. Open the sunshade to the full open position. 2. Open the sunroof window to the full open
position.
1. Unhook the wind deflector slide blocks (1) from each side. 2. Unhook the wind deflector tabs (2)
from the rear of the upper frame. 3. Remove the wind deflector.
Installation Procedure
1. The window Must be in the full open position to do the following:
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Moonroof Windguard > Component Information > Service and Repair > Page 10364
1. Install the wind deflector to the upper frame. 2. Hook the wind deflector slide blocks (1) to each
side. 3. Hook the wind deflector tabs (2) into the rear of the upper frame. 4. Verify operation of the
wind deflector.
2. Verify operations of the sunroof window. 3. Close the sunroof.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame:
> 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof
Sunroof / Moonroof Frame: Customer Interest Body - Water leaks/ Wind Noise From The Sunroof
TECHNICAL
Bulletin No.: 07-08-67-001B
Date: June 22, 2009
Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and
Apply Sealer)
Models:
2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof
Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate
Bulletin 07-08-67-001A (Section 08 - Body & Accessories).
Condition
Some customers may comment on water entering into the vehicle from the sunroof area. Other
customers may comment on a wind noise or whistle noise heard from the sunroof area when
driving at different speeds.
Design
The sunroof module is designed to be completely sealed at the roof panel to help prevent water
from traveling past the glass panel seal. The sunroof glass assembly does not have any glass
panel adjustments. The sunroof assembly does not contain a water management drain tube
system. When operating the sunroof, the glass panel moves rearward and slides up above the roof
panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove
excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some
water may enter inside the vehicle.
Cause
Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the
upper sunroof frame assembly.
Wind or Whistle Noise Test Procedure
Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI.
Water Hose Test Procedure
Perform a water hose test to determine where the leak is entering the sunroof assembly.
Important Use a water hose without the nozzle attached at a controlled medium volume water flow.
1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1)
like in the graphic above is not flush, make sure
no parts are broken or missing from the sunroof module assembly.
2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with
warm water to clean the seals. Use GM(TM) Glass
Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks.
3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open
position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6.
Remove the outer trim cover.
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Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame:
> 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10373
7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8.
Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water
test to verify the leak concern.
10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of
the following four areas:
1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be
entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the
sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip
holder.
11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire
outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking
tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one
inch of tape at a time until the source of the leak can be
pinpointed.
14. Proceed with the water test while removing the masking tape along the right front outer sunroof
frame and roof panel until the complete area has
been tested.
15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame
with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start
water testing while removing the masking tape from the left front corner of the sunroof glass; then
proceed along to the right front corner of
the glass until the complete area has been tested.
18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing
and mark the entry point of the water. 20. The leak could be from more than one area, so
determine which conditions apply and follow the recommended corrections below.
Condition 1
The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof
frame.
Cause 1
The dry foam seal on the upper sunroof frame assembly may have collapsed or has become
distorted, causing the leak.
Correction 1
Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to
the outer edge of the upper sunroof frame using the procedure listed below:
1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI.
Important Note the size, color and locations of the lower sunroof frame screws when removing
them.
2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame.
Important Do Not remove the (red) TORX(R) screws from the track.
3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower
frame from the sunroof module assembly.
Important Have a clean workbench with a flat protective cover. The cover will help protect the
sunroof glass when the glass is placed face down on the bench.
5. Remove the sunroof module and window from the vehicle and place the glass side down on a
clean bench.
Tip The sunroof window can now be manually moved forward or backward.
6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of
the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the
sunroof frame. If the
sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame:
> 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10374
8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if
no adhesive has been used. If adhesive has been
used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner,
P/N 08984, or equivalent, to clean the roof panel.
9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare
edges of the roof panel opening for the sunroof
module. This grease is recommended for use on any bare edges around the sunroof opening. An
acid brush can be used to apply the grease.
10. A caulk gun applicator will be needed to apply the adhesive (1).
Tip You may want to use some disposable gloves to keep the adhesive from getting onto your
hands.
11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame
assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install
the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame
assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Manually push the sunroof window to the full open position. This will allow the window, motors
and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement
in SI. 18. Verify the proper operation of the sunroof.
19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade
while using a 3M(TM) General Purpose Cleaner,
P/N 08984, or equivalent, as shown in the graphic above.
20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover.
Refer to Sunroof Front Trim Cover Replacement in SI.
Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open
the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are
installed properly.
22. Install the outer trim cover and four screws.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame:
> 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10375
Tighten Tighten the screws to 1 Nm (9 lb in).
Condition 2
A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the
window weather seal (4).
Cause 2
The seal on the upper sunroof frame assembly may not have enough sealant under the seal.
Correction 2
Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip
sealing flange located in the upper sunroof frame.
Condition 3
A leak from the sunroof window glass and sunroof window seal.
Cause 3
The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass
to seal properly.
Correction 3
Replace the sunroof window seal following the steps below:
1. Open the sunshade to the full open position.
2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal
Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame:
> 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10376
Condition 4
A leak from around the sunroof glass holder clip, known as a "blow out clip" (1).
Cause 4
A lack of adhesive sealant under the sunroof window holder clip.
Correction 4
Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the
upper frame clip using the steps below.
1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove
the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two
screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the
two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to
the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws.
Tighten Tighten the two screws to 1 Nm (9 lb in).
Important The chamfered edge of the gear goes toward the motor when reinstalling the gear.
10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws.
Tighten Tighten the screw to 2 Nm (18 lb in).
13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install
the sunroof motor assembly. 15. Install the sunroof motor screws and tighten.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim
cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and
four screws.
Tighten Tighten the screws to 1 Nm (9 lb in).
Waterleak Odor in Vehicle
Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles.
Dry out any wet components. Refer to Floor Carpet Drying in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
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> 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10377
Parts Information
To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144
from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to
place orders. The dealer also has the option to complete a referral request form to purchase the
product through a local supplier.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof
Sunroof / Moonroof Frame: All Technical Service Bulletins Body - Water leaks/ Wind Noise From
The Sunroof
TECHNICAL
Bulletin No.: 07-08-67-001B
Date: June 22, 2009
Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and
Apply Sealer)
Models:
2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof
Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate
Bulletin 07-08-67-001A (Section 08 - Body & Accessories).
Condition
Some customers may comment on water entering into the vehicle from the sunroof area. Other
customers may comment on a wind noise or whistle noise heard from the sunroof area when
driving at different speeds.
Design
The sunroof module is designed to be completely sealed at the roof panel to help prevent water
from traveling past the glass panel seal. The sunroof glass assembly does not have any glass
panel adjustments. The sunroof assembly does not contain a water management drain tube
system. When operating the sunroof, the glass panel moves rearward and slides up above the roof
panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove
excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some
water may enter inside the vehicle.
Cause
Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the
upper sunroof frame assembly.
Wind or Whistle Noise Test Procedure
Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI.
Water Hose Test Procedure
Perform a water hose test to determine where the leak is entering the sunroof assembly.
Important Use a water hose without the nozzle attached at a controlled medium volume water flow.
1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1)
like in the graphic above is not flush, make sure
no parts are broken or missing from the sunroof module assembly.
2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with
warm water to clean the seals. Use GM(TM) Glass
Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks.
3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open
position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6.
Remove the outer trim cover.
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Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10383
7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8.
Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water
test to verify the leak concern.
10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of
the following four areas:
1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be
entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the
sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip
holder.
11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire
outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking
tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one
inch of tape at a time until the source of the leak can be
pinpointed.
14. Proceed with the water test while removing the masking tape along the right front outer sunroof
frame and roof panel until the complete area has
been tested.
15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame
with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start
water testing while removing the masking tape from the left front corner of the sunroof glass; then
proceed along to the right front corner of
the glass until the complete area has been tested.
18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing
and mark the entry point of the water. 20. The leak could be from more than one area, so
determine which conditions apply and follow the recommended corrections below.
Condition 1
The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof
frame.
Cause 1
The dry foam seal on the upper sunroof frame assembly may have collapsed or has become
distorted, causing the leak.
Correction 1
Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to
the outer edge of the upper sunroof frame using the procedure listed below:
1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI.
Important Note the size, color and locations of the lower sunroof frame screws when removing
them.
2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame.
Important Do Not remove the (red) TORX(R) screws from the track.
3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower
frame from the sunroof module assembly.
Important Have a clean workbench with a flat protective cover. The cover will help protect the
sunroof glass when the glass is placed face down on the bench.
5. Remove the sunroof module and window from the vehicle and place the glass side down on a
clean bench.
Tip The sunroof window can now be manually moved forward or backward.
6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of
the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the
sunroof frame. If the
sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
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Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10384
8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if
no adhesive has been used. If adhesive has been
used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner,
P/N 08984, or equivalent, to clean the roof panel.
9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare
edges of the roof panel opening for the sunroof
module. This grease is recommended for use on any bare edges around the sunroof opening. An
acid brush can be used to apply the grease.
10. A caulk gun applicator will be needed to apply the adhesive (1).
Tip You may want to use some disposable gloves to keep the adhesive from getting onto your
hands.
11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame
assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install
the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame
assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Manually push the sunroof window to the full open position. This will allow the window, motors
and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement
in SI. 18. Verify the proper operation of the sunroof.
19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade
while using a 3M(TM) General Purpose Cleaner,
P/N 08984, or equivalent, as shown in the graphic above.
20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover.
Refer to Sunroof Front Trim Cover Replacement in SI.
Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open
the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are
installed properly.
22. Install the outer trim cover and four screws.
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Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10385
Tighten Tighten the screws to 1 Nm (9 lb in).
Condition 2
A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the
window weather seal (4).
Cause 2
The seal on the upper sunroof frame assembly may not have enough sealant under the seal.
Correction 2
Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip
sealing flange located in the upper sunroof frame.
Condition 3
A leak from the sunroof window glass and sunroof window seal.
Cause 3
The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass
to seal properly.
Correction 3
Replace the sunroof window seal following the steps below:
1. Open the sunshade to the full open position.
2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal
Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10386
Condition 4
A leak from around the sunroof glass holder clip, known as a "blow out clip" (1).
Cause 4
A lack of adhesive sealant under the sunroof window holder clip.
Correction 4
Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the
upper frame clip using the steps below.
1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove
the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two
screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the
two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to
the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws.
Tighten Tighten the two screws to 1 Nm (9 lb in).
Important The chamfered edge of the gear goes toward the motor when reinstalling the gear.
10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws.
Tighten Tighten the screw to 2 Nm (18 lb in).
13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install
the sunroof motor assembly. 15. Install the sunroof motor screws and tighten.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim
cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and
four screws.
Tighten Tighten the screws to 1 Nm (9 lb in).
Waterleak Odor in Vehicle
Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles.
Dry out any wet components. Refer to Floor Carpet Drying in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10387
Parts Information
To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144
from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to
place orders. The dealer also has the option to complete a referral request form to purchase the
product through a local supplier.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper
Sunroof / Moonroof Frame: Service and Repair Sunroof Frame Replacement - Upper
Sunroof Frame Replacement - Upper
Removal Procedure
1. Open the sunshade to the full open position. 2. Open the sunroof window to the full open
position. 3. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement
(See: Sunroof / Moonroof Interior Trim Panel/Service and
Repair).
4. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement (See: Sunroof /
Moonroof Motor/Service and Repair).
Note: Note the location of the bolts, size and color when removing, for proper installation.
5. Remove the screws from around the lower frame. Refer to Sunroof Frame Replacement - Lower
(See: Sunroof Frame Replacement - Lower).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10390
Note: Place the sunroof module on a flat protective cover, face down.
6. Remove the sunroof module and window from the vehicle.
7. Remove the cam plate screws (1). 8. Remove the cam plate (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10391
9. Lift upward on the drive cables (2) to release the cam (3) from the upper frame.
10. Remove the left and right side drive cable tube covers (1), two on each side. 11. Push the drive
cables up into the upper frame, this will allow the window to open manually.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10392
Note: Place the sunroof module on a flat protective cover, face down.
12. The sunroof window must be in the full open position to do the following:
1. Unhook the wind deflector slide blocks (1) from each side. 2. Unhook the wind deflector tabs (2)
from the center of the upper frame. 3. Remove the wind deflector.
Note: Mark the left and right sides of the guides in respect to the frame. This will assist in the
alignment of the window to the module later.
Note the location of the bolts, size and color when removing, for proper installation.
13. Remove the two screws (1) on each side of the guides (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10393
Note: Place the sunroof module on a flat protective cover, face down. It is necessary to slide the
guides about 1 cm (1 3/8 in) rearward to release the upper frame.
14. Rotate the upper frame back and fourth. Pushing forward on the upper frame until it is over the
guides.
15. Remove the upper frame (2) from the window and guides (1).
Do not remove the drive cables or sliders from the guides.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10394
1. Install the upper frame (2) to the window and guides (1).
Note: Place the sunroof module on a flat protective cover, face down. Rotate the upper frame back
and fourth until it is over the guides. Refer to the marked positions on the guides in respect to the
frame.
2. Place the guides about 1 cm (1 3/8 in) rearward to reinstall the upper frame. 3. Pull rearward on
the upper frame until the screws holes align with the guide holes.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10395
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Note: Using the marks on the left and right sides of the guides to reinstall the window to the module
for alignment.
4. Install the two screws (1) to each side of the guides (2).
Install the bolts, size and color to the proper location.
Tighten the screw to 3 Nm (27 lb in).
Note: Place the sunroof module on a flat protective cover, face down.
5. The window must be in the full open position to do the following:
1. Install the wind deflector. 2. Hook the wind deflector slide blocks (1) to each side. 3. Hook the
wind deflector tabs (2) to the center of the upper frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10396
6. Install the left and right side drive cable tube covers (1), two drive cable tube covers to each side
Note: Ensure that the chamfered edge of the gear is directed upward.
7. Install the drive cables (2) with cam (3) to the sunroof module.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10397
8. Install the cam plate (2). 9. Install the cam plate screws (1).
Tighten the cam plate screw to 3 Nm (27 lb in).
10. Manually close the sunroof window to the sunroof module assembly on the bench.
11. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built
without adhesive under the sunroof frame. If the
sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10398
12. Clean the old sealer (1) from the opening of the roof outside roof panel area around the sunroof
opening with GM(TM) Glass Cleaner if no
adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and
a 3M(TM) General Purpose Adhesive Cleaner P/N 08984 or equivalent to clean the roof panel.
13. Apply synthetic lubrication with Teflon GM P/N 12371287 (Canadian P/N 10953437) to the
outside bare edges of the roof panel opening for the
sunroof module. This grease is recommended for use on any bare edges around the sunroof
opening. An acid brush can be used to apply the grease.
Note: You may want to use some disposable gloves to keep the adhesive from getting onto your
hand.
14. A caulk gun applicator will be needed to apply the adhesive. 15. Apply a 2 mm (1 1/16 in) bead
of CRL7711 or 3M(TM) P/N 08506 Clear or P/N 08509 Black sealant around the entire edge of the
upper frame
assembly and dry seal.
16. Install the sunroof module assembly into the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10399
17. Install the lower sunroof frame to the sunroof module. 18. Install the screws into the proper
locations of the lower sunroof frame assembly. 19. Tighten the screws in the lower sunroof frame
using a cross-tightening sequence.
Tighten the screws to 3 Nm (27 lb in).
20. Place the sunroof window to the full open position. This will allow the window, motor and cables
to be timed. Refer to Sunroof Track
Timing/Synchronization (See: Sunroof / Moonroof Track/Service and Repair/Procedures).
21. Install the sunroof motor. Refer to Power Sunroof Motor Replacement (See: Sunroof / Moonroof
Motor/Service and Repair). 22. Close the sunroof window fully. 23. Verify proper operation of the
sunroof.
24. Clean any excessive adhesive off the roof panel with a plastic-type scraper/razor blade and a
3M(TM) General Purpose Cleaner P/N 08984 or
equivalent.
25. Perform a water test to verify the leak has been fixed. 26. Install the sunroof front trim cover.
Refer to Sunroof Front Trim Cover Replacement (See: Sunroof / Moonroof Interior Trim
Panel/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10400
Sunroof / Moonroof Frame: Service and Repair Sunroof Frame Replacement - Lower
Sunroof Frame Replacement - Lower
Removal Procedure
1. Open the sunshade to the full open position. 2. Remove the sunroof front trim cover. Refer to
Sunroof Front Trim Cover Replacement (See: Sunroof / Moonroof Interior Trim Panel/Service and
Repair).
3. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement (See: Sunroof /
Moonroof Motor/Service and Repair).
Note: Note the location of the bolts, size and color when removing, for proper installation.
4. Remove the screws from around the lower frame. 5. Remove the lower frame from sunroof
module.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10401
1. Install the lower frame to the sunroof module.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Tighten the screws to the lower frame of the sunroof module.
Install the bolts, size and color to the proper location.
Tighten the screw to 3 Nm (27 lb in).
3. Push the sunroof window to the full open position. This will allow the window, motor and cables
to be timed. 4. Install the sunroof motor. Refer to Power Sunroof Motor Replacement (See: Sunroof
/ Moonroof Motor/Service and Repair). 5. Install the sunroof front trim cover. Refer to Sunroof Front
Trim Cover Replacement (See: Sunroof / Moonroof Interior Trim Panel/Service and
Repair).
6. Verify operations of the sunroof window.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Gear Assembly > Component Information > Service and Repair
Sunroof / Moonroof Gear Assembly: Service and Repair
Sunroof Cam Assembly Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Interior Trim Panel > Component Information > Service and Repair
Sunroof / Moonroof Interior Trim Panel: Service and Repair
Sunroof Front Trim Cover Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Panel:
> 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof
Sunroof / Moonroof Panel: Customer Interest Body - Water leaks/ Wind Noise From The Sunroof
TECHNICAL
Bulletin No.: 07-08-67-001B
Date: June 22, 2009
Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and
Apply Sealer)
Models:
2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof
Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate
Bulletin 07-08-67-001A (Section 08 - Body & Accessories).
Condition
Some customers may comment on water entering into the vehicle from the sunroof area. Other
customers may comment on a wind noise or whistle noise heard from the sunroof area when
driving at different speeds.
Design
The sunroof module is designed to be completely sealed at the roof panel to help prevent water
from traveling past the glass panel seal. The sunroof glass assembly does not have any glass
panel adjustments. The sunroof assembly does not contain a water management drain tube
system. When operating the sunroof, the glass panel moves rearward and slides up above the roof
panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove
excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some
water may enter inside the vehicle.
Cause
Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the
upper sunroof frame assembly.
Wind or Whistle Noise Test Procedure
Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI.
Water Hose Test Procedure
Perform a water hose test to determine where the leak is entering the sunroof assembly.
Important Use a water hose without the nozzle attached at a controlled medium volume water flow.
1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1)
like in the graphic above is not flush, make sure
no parts are broken or missing from the sunroof module assembly.
2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with
warm water to clean the seals. Use GM(TM) Glass
Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks.
3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open
position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6.
Remove the outer trim cover.
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Moonroof Panel > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Panel:
> 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10416
7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8.
Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water
test to verify the leak concern.
10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of
the following four areas:
1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be
entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the
sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip
holder.
11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire
outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking
tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one
inch of tape at a time until the source of the leak can be
pinpointed.
14. Proceed with the water test while removing the masking tape along the right front outer sunroof
frame and roof panel until the complete area has
been tested.
15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame
with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start
water testing while removing the masking tape from the left front corner of the sunroof glass; then
proceed along to the right front corner of
the glass until the complete area has been tested.
18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing
and mark the entry point of the water. 20. The leak could be from more than one area, so
determine which conditions apply and follow the recommended corrections below.
Condition 1
The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof
frame.
Cause 1
The dry foam seal on the upper sunroof frame assembly may have collapsed or has become
distorted, causing the leak.
Correction 1
Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to
the outer edge of the upper sunroof frame using the procedure listed below:
1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI.
Important Note the size, color and locations of the lower sunroof frame screws when removing
them.
2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame.
Important Do Not remove the (red) TORX(R) screws from the track.
3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower
frame from the sunroof module assembly.
Important Have a clean workbench with a flat protective cover. The cover will help protect the
sunroof glass when the glass is placed face down on the bench.
5. Remove the sunroof module and window from the vehicle and place the glass side down on a
clean bench.
Tip The sunroof window can now be manually moved forward or backward.
6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of
the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the
sunroof frame. If the
sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Panel:
> 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10417
8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if
no adhesive has been used. If adhesive has been
used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner,
P/N 08984, or equivalent, to clean the roof panel.
9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare
edges of the roof panel opening for the sunroof
module. This grease is recommended for use on any bare edges around the sunroof opening. An
acid brush can be used to apply the grease.
10. A caulk gun applicator will be needed to apply the adhesive (1).
Tip You may want to use some disposable gloves to keep the adhesive from getting onto your
hands.
11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame
assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install
the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame
assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Manually push the sunroof window to the full open position. This will allow the window, motors
and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement
in SI. 18. Verify the proper operation of the sunroof.
19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade
while using a 3M(TM) General Purpose Cleaner,
P/N 08984, or equivalent, as shown in the graphic above.
20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover.
Refer to Sunroof Front Trim Cover Replacement in SI.
Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open
the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are
installed properly.
22. Install the outer trim cover and four screws.
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Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Panel:
> 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10418
Tighten Tighten the screws to 1 Nm (9 lb in).
Condition 2
A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the
window weather seal (4).
Cause 2
The seal on the upper sunroof frame assembly may not have enough sealant under the seal.
Correction 2
Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip
sealing flange located in the upper sunroof frame.
Condition 3
A leak from the sunroof window glass and sunroof window seal.
Cause 3
The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass
to seal properly.
Correction 3
Replace the sunroof window seal following the steps below:
1. Open the sunshade to the full open position.
2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal
Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Panel:
> 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10419
Condition 4
A leak from around the sunroof glass holder clip, known as a "blow out clip" (1).
Cause 4
A lack of adhesive sealant under the sunroof window holder clip.
Correction 4
Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the
upper frame clip using the steps below.
1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove
the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two
screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the
two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to
the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws.
Tighten Tighten the two screws to 1 Nm (9 lb in).
Important The chamfered edge of the gear goes toward the motor when reinstalling the gear.
10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws.
Tighten Tighten the screw to 2 Nm (18 lb in).
13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install
the sunroof motor assembly. 15. Install the sunroof motor screws and tighten.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim
cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and
four screws.
Tighten Tighten the screws to 1 Nm (9 lb in).
Waterleak Odor in Vehicle
Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles.
Dry out any wet components. Refer to Floor Carpet Drying in SI.
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Moonroof Panel > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Panel:
> 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10420
Parts Information
To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144
from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to
place orders. The dealer also has the option to complete a referral request form to purchase the
product through a local supplier.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof
Sunroof / Moonroof Panel: All Technical Service Bulletins Body - Water leaks/ Wind Noise From
The Sunroof
TECHNICAL
Bulletin No.: 07-08-67-001B
Date: June 22, 2009
Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and
Apply Sealer)
Models:
2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof
Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate
Bulletin 07-08-67-001A (Section 08 - Body & Accessories).
Condition
Some customers may comment on water entering into the vehicle from the sunroof area. Other
customers may comment on a wind noise or whistle noise heard from the sunroof area when
driving at different speeds.
Design
The sunroof module is designed to be completely sealed at the roof panel to help prevent water
from traveling past the glass panel seal. The sunroof glass assembly does not have any glass
panel adjustments. The sunroof assembly does not contain a water management drain tube
system. When operating the sunroof, the glass panel moves rearward and slides up above the roof
panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove
excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some
water may enter inside the vehicle.
Cause
Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the
upper sunroof frame assembly.
Wind or Whistle Noise Test Procedure
Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI.
Water Hose Test Procedure
Perform a water hose test to determine where the leak is entering the sunroof assembly.
Important Use a water hose without the nozzle attached at a controlled medium volume water flow.
1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1)
like in the graphic above is not flush, make sure
no parts are broken or missing from the sunroof module assembly.
2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with
warm water to clean the seals. Use GM(TM) Glass
Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks.
3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open
position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6.
Remove the outer trim cover.
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Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10426
7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8.
Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water
test to verify the leak concern.
10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of
the following four areas:
1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be
entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the
sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip
holder.
11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire
outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking
tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one
inch of tape at a time until the source of the leak can be
pinpointed.
14. Proceed with the water test while removing the masking tape along the right front outer sunroof
frame and roof panel until the complete area has
been tested.
15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame
with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start
water testing while removing the masking tape from the left front corner of the sunroof glass; then
proceed along to the right front corner of
the glass until the complete area has been tested.
18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing
and mark the entry point of the water. 20. The leak could be from more than one area, so
determine which conditions apply and follow the recommended corrections below.
Condition 1
The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof
frame.
Cause 1
The dry foam seal on the upper sunroof frame assembly may have collapsed or has become
distorted, causing the leak.
Correction 1
Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to
the outer edge of the upper sunroof frame using the procedure listed below:
1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI.
Important Note the size, color and locations of the lower sunroof frame screws when removing
them.
2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame.
Important Do Not remove the (red) TORX(R) screws from the track.
3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower
frame from the sunroof module assembly.
Important Have a clean workbench with a flat protective cover. The cover will help protect the
sunroof glass when the glass is placed face down on the bench.
5. Remove the sunroof module and window from the vehicle and place the glass side down on a
clean bench.
Tip The sunroof window can now be manually moved forward or backward.
6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of
the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the
sunroof frame. If the
sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10427
8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if
no adhesive has been used. If adhesive has been
used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner,
P/N 08984, or equivalent, to clean the roof panel.
9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare
edges of the roof panel opening for the sunroof
module. This grease is recommended for use on any bare edges around the sunroof opening. An
acid brush can be used to apply the grease.
10. A caulk gun applicator will be needed to apply the adhesive (1).
Tip You may want to use some disposable gloves to keep the adhesive from getting onto your
hands.
11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame
assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install
the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame
assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Manually push the sunroof window to the full open position. This will allow the window, motors
and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement
in SI. 18. Verify the proper operation of the sunroof.
19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade
while using a 3M(TM) General Purpose Cleaner,
P/N 08984, or equivalent, as shown in the graphic above.
20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover.
Refer to Sunroof Front Trim Cover Replacement in SI.
Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open
the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are
installed properly.
22. Install the outer trim cover and four screws.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10428
Tighten Tighten the screws to 1 Nm (9 lb in).
Condition 2
A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the
window weather seal (4).
Cause 2
The seal on the upper sunroof frame assembly may not have enough sealant under the seal.
Correction 2
Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip
sealing flange located in the upper sunroof frame.
Condition 3
A leak from the sunroof window glass and sunroof window seal.
Cause 3
The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass
to seal properly.
Correction 3
Replace the sunroof window seal following the steps below:
1. Open the sunshade to the full open position.
2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal
Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10429
Condition 4
A leak from around the sunroof glass holder clip, known as a "blow out clip" (1).
Cause 4
A lack of adhesive sealant under the sunroof window holder clip.
Correction 4
Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the
upper frame clip using the steps below.
1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove
the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two
screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the
two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to
the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws.
Tighten Tighten the two screws to 1 Nm (9 lb in).
Important The chamfered edge of the gear goes toward the motor when reinstalling the gear.
10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws.
Tighten Tighten the screw to 2 Nm (18 lb in).
13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install
the sunroof motor assembly. 15. Install the sunroof motor screws and tighten.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim
cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and
four screws.
Tighten Tighten the screws to 1 Nm (9 lb in).
Waterleak Odor in Vehicle
Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles.
Dry out any wet components. Refer to Floor Carpet Drying in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10430
Parts Information
To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144
from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to
place orders. The dealer also has the option to complete a referral request form to purchase the
product through a local supplier.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > Page 10431
Sunroof / Moonroof Panel: Service and Repair
Sunroof Window Replacement
Removal Procedure
1. Remove the sunroof module guides. Refer to Sunroof Guide Replacement (See: Sunroof /
Moonroof Track/Service and Repair/Removal and
Replacement/Sunroof Guide Replacement).
Important: Place the sunroof module on a protective cover, face down.
2. Remove the sunroof module sliders. Refer to Sunroof Sliding Block Guide Replacement (See:
Sunroof / Moonroof Track/Service and
Repair/Removal and Replacement/Sunroof Sliding Block Guide Replacement).
Important: Mark the left and right sides of the guides in respect to the frame. This will assist in the
alignment of the window to the module later.
3. Remove the guides (1) from the left and right.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > Page 10432
4. Remove the drive cables (1) and sliders (2) from the guides.
5. Remove the locker slider (1).
1. Rotate the lever forward, slide the locker slider forward. 2. Carefully remove the lever, using a
suitable tool by inserting it between the track and the lever.
The track is not serviceable, if damaged replace the sunroof window.
6. Remove the sunroof window from the module.
Installation Procedure
1. Install the sunroof window to the module.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > Page 10433
2. Install the locker slider (1).
1. Rotate the lever forward, align the locker slider with the hole in the lever and slider forward. 2.
Using a suitable tool, insert it between the track and the lever to lock it in place.
The track is not serviceable, if damaged replace the sunroof window.
3. Install the drive cables (1) and sliders (2) to the guides.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Technical Service Bulletins > Page 10434
Important: Using the marks on the left and right sides of the guides to reinstall the window to the
module for alignment.
4. Install the sunroof module guides (1) to the left and right. 5. Install the sunroof module sliders.
Refer to Sunroof Sliding Block Guide Replacement (See: Sunroof / Moonroof Track/Service and
Repair/Removal and Replacement/Sunroof Sliding Block Guide Replacement).
6. Install the sunroof module guides. Refer to Sunroof Guide Replacement (See: Sunroof /
Moonroof Track/Service and Repair/Removal and
Replacement/Sunroof Guide Replacement).
7. Verify operations of the sunroof window.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof
Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof
Sunroof / Moonroof Weatherstrip: Customer Interest Body - Water leaks/ Wind Noise From The
Sunroof
TECHNICAL
Bulletin No.: 07-08-67-001B
Date: June 22, 2009
Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and
Apply Sealer)
Models:
2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof
Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate
Bulletin 07-08-67-001A (Section 08 - Body & Accessories).
Condition
Some customers may comment on water entering into the vehicle from the sunroof area. Other
customers may comment on a wind noise or whistle noise heard from the sunroof area when
driving at different speeds.
Design
The sunroof module is designed to be completely sealed at the roof panel to help prevent water
from traveling past the glass panel seal. The sunroof glass assembly does not have any glass
panel adjustments. The sunroof assembly does not contain a water management drain tube
system. When operating the sunroof, the glass panel moves rearward and slides up above the roof
panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove
excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some
water may enter inside the vehicle.
Cause
Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the
upper sunroof frame assembly.
Wind or Whistle Noise Test Procedure
Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI.
Water Hose Test Procedure
Perform a water hose test to determine where the leak is entering the sunroof assembly.
Important Use a water hose without the nozzle attached at a controlled medium volume water flow.
1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1)
like in the graphic above is not flush, make sure
no parts are broken or missing from the sunroof module assembly.
2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with
warm water to clean the seals. Use GM(TM) Glass
Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks.
3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open
position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6.
Remove the outer trim cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof
Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10443
7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8.
Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water
test to verify the leak concern.
10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of
the following four areas:
1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be
entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the
sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip
holder.
11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire
outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking
tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one
inch of tape at a time until the source of the leak can be
pinpointed.
14. Proceed with the water test while removing the masking tape along the right front outer sunroof
frame and roof panel until the complete area has
been tested.
15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame
with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start
water testing while removing the masking tape from the left front corner of the sunroof glass; then
proceed along to the right front corner of
the glass until the complete area has been tested.
18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing
and mark the entry point of the water. 20. The leak could be from more than one area, so
determine which conditions apply and follow the recommended corrections below.
Condition 1
The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof
frame.
Cause 1
The dry foam seal on the upper sunroof frame assembly may have collapsed or has become
distorted, causing the leak.
Correction 1
Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to
the outer edge of the upper sunroof frame using the procedure listed below:
1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI.
Important Note the size, color and locations of the lower sunroof frame screws when removing
them.
2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame.
Important Do Not remove the (red) TORX(R) screws from the track.
3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower
frame from the sunroof module assembly.
Important Have a clean workbench with a flat protective cover. The cover will help protect the
sunroof glass when the glass is placed face down on the bench.
5. Remove the sunroof module and window from the vehicle and place the glass side down on a
clean bench.
Tip The sunroof window can now be manually moved forward or backward.
6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of
the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the
sunroof frame. If the
sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof
Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10444
8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if
no adhesive has been used. If adhesive has been
used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner,
P/N 08984, or equivalent, to clean the roof panel.
9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare
edges of the roof panel opening for the sunroof
module. This grease is recommended for use on any bare edges around the sunroof opening. An
acid brush can be used to apply the grease.
10. A caulk gun applicator will be needed to apply the adhesive (1).
Tip You may want to use some disposable gloves to keep the adhesive from getting onto your
hands.
11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame
assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install
the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame
assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Manually push the sunroof window to the full open position. This will allow the window, motors
and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement
in SI. 18. Verify the proper operation of the sunroof.
19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade
while using a 3M(TM) General Purpose Cleaner,
P/N 08984, or equivalent, as shown in the graphic above.
20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover.
Refer to Sunroof Front Trim Cover Replacement in SI.
Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open
the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are
installed properly.
22. Install the outer trim cover and four screws.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof
Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10445
Tighten Tighten the screws to 1 Nm (9 lb in).
Condition 2
A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the
window weather seal (4).
Cause 2
The seal on the upper sunroof frame assembly may not have enough sealant under the seal.
Correction 2
Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip
sealing flange located in the upper sunroof frame.
Condition 3
A leak from the sunroof window glass and sunroof window seal.
Cause 3
The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass
to seal properly.
Correction 3
Replace the sunroof window seal following the steps below:
1. Open the sunshade to the full open position.
2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal
Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof
Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10446
Condition 4
A leak from around the sunroof glass holder clip, known as a "blow out clip" (1).
Cause 4
A lack of adhesive sealant under the sunroof window holder clip.
Correction 4
Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the
upper frame clip using the steps below.
1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove
the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two
screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the
two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to
the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws.
Tighten Tighten the two screws to 1 Nm (9 lb in).
Important The chamfered edge of the gear goes toward the motor when reinstalling the gear.
10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws.
Tighten Tighten the screw to 2 Nm (18 lb in).
13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install
the sunroof motor assembly. 15. Install the sunroof motor screws and tighten.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim
cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and
four screws.
Tighten Tighten the screws to 1 Nm (9 lb in).
Waterleak Odor in Vehicle
Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles.
Dry out any wet components. Refer to Floor Carpet Drying in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof
Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10447
Parts Information
To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144
from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to
place orders. The dealer also has the option to complete a referral request form to purchase the
product through a local supplier.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof
/ Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof
Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Water leaks/ Wind Noise
From The Sunroof
TECHNICAL
Bulletin No.: 07-08-67-001B
Date: June 22, 2009
Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and
Apply Sealer)
Models:
2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof
Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate
Bulletin 07-08-67-001A (Section 08 - Body & Accessories).
Condition
Some customers may comment on water entering into the vehicle from the sunroof area. Other
customers may comment on a wind noise or whistle noise heard from the sunroof area when
driving at different speeds.
Design
The sunroof module is designed to be completely sealed at the roof panel to help prevent water
from traveling past the glass panel seal. The sunroof glass assembly does not have any glass
panel adjustments. The sunroof assembly does not contain a water management drain tube
system. When operating the sunroof, the glass panel moves rearward and slides up above the roof
panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove
excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some
water may enter inside the vehicle.
Cause
Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the
upper sunroof frame assembly.
Wind or Whistle Noise Test Procedure
Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI.
Water Hose Test Procedure
Perform a water hose test to determine where the leak is entering the sunroof assembly.
Important Use a water hose without the nozzle attached at a controlled medium volume water flow.
1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1)
like in the graphic above is not flush, make sure
no parts are broken or missing from the sunroof module assembly.
2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with
warm water to clean the seals. Use GM(TM) Glass
Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks.
3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open
position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6.
Remove the outer trim cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof
/ Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10453
7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8.
Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water
test to verify the leak concern.
10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of
the following four areas:
1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be
entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the
sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip
holder.
11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire
outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking
tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one
inch of tape at a time until the source of the leak can be
pinpointed.
14. Proceed with the water test while removing the masking tape along the right front outer sunroof
frame and roof panel until the complete area has
been tested.
15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame
with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start
water testing while removing the masking tape from the left front corner of the sunroof glass; then
proceed along to the right front corner of
the glass until the complete area has been tested.
18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing
and mark the entry point of the water. 20. The leak could be from more than one area, so
determine which conditions apply and follow the recommended corrections below.
Condition 1
The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof
frame.
Cause 1
The dry foam seal on the upper sunroof frame assembly may have collapsed or has become
distorted, causing the leak.
Correction 1
Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to
the outer edge of the upper sunroof frame using the procedure listed below:
1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI.
Important Note the size, color and locations of the lower sunroof frame screws when removing
them.
2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame.
Important Do Not remove the (red) TORX(R) screws from the track.
3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower
frame from the sunroof module assembly.
Important Have a clean workbench with a flat protective cover. The cover will help protect the
sunroof glass when the glass is placed face down on the bench.
5. Remove the sunroof module and window from the vehicle and place the glass side down on a
clean bench.
Tip The sunroof window can now be manually moved forward or backward.
6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of
the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the
sunroof frame. If the
sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof
/ Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10454
8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if
no adhesive has been used. If adhesive has been
used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner,
P/N 08984, or equivalent, to clean the roof panel.
9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare
edges of the roof panel opening for the sunroof
module. This grease is recommended for use on any bare edges around the sunroof opening. An
acid brush can be used to apply the grease.
10. A caulk gun applicator will be needed to apply the adhesive (1).
Tip You may want to use some disposable gloves to keep the adhesive from getting onto your
hands.
11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame
assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install
the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame
assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Manually push the sunroof window to the full open position. This will allow the window, motors
and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement
in SI. 18. Verify the proper operation of the sunroof.
19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade
while using a 3M(TM) General Purpose Cleaner,
P/N 08984, or equivalent, as shown in the graphic above.
20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover.
Refer to Sunroof Front Trim Cover Replacement in SI.
Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open
the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are
installed properly.
22. Install the outer trim cover and four screws.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof
/ Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10455
Tighten Tighten the screws to 1 Nm (9 lb in).
Condition 2
A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the
window weather seal (4).
Cause 2
The seal on the upper sunroof frame assembly may not have enough sealant under the seal.
Correction 2
Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip
sealing flange located in the upper sunroof frame.
Condition 3
A leak from the sunroof window glass and sunroof window seal.
Cause 3
The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass
to seal properly.
Correction 3
Replace the sunroof window seal following the steps below:
1. Open the sunshade to the full open position.
2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal
Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof
/ Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10456
Condition 4
A leak from around the sunroof glass holder clip, known as a "blow out clip" (1).
Cause 4
A lack of adhesive sealant under the sunroof window holder clip.
Correction 4
Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the
upper frame clip using the steps below.
1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove
the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two
screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the
two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to
the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws.
Tighten Tighten the two screws to 1 Nm (9 lb in).
Important The chamfered edge of the gear goes toward the motor when reinstalling the gear.
10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws.
Tighten Tighten the screw to 2 Nm (18 lb in).
13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install
the sunroof motor assembly. 15. Install the sunroof motor screws and tighten.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim
cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and
four screws.
Tighten Tighten the screws to 1 Nm (9 lb in).
Waterleak Odor in Vehicle
Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles.
Dry out any wet components. Refer to Floor Carpet Drying in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof
/ Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10457
Parts Information
To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144
from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to
place orders. The dealer also has the option to complete a referral request form to purchase the
product through a local supplier.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10458
Sunroof / Moonroof Weatherstrip: Service and Repair
Sunroof Window Seal Replacement
Removal Procedure
1. Open the sunshade to the full open position.
2. Remove the sunroof window seal (1) from the upper frame (2).
1. Carefully remove the old seal. 2. Open the sunroof window completely when working along the
front and sides. 3. Move the sunroof window into the maximum tilt position when working on the
rear side.
3. Remove the sunroof window seal from the upper frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10459
4. Remove all traces of sealant from around the inside upper frame groove to prevent leaks.
5. Clean the upper frame as follows, clean around the inside surface and edges with a 50/50
mixture of isopropyl alcohol and water by volume on a
dampened lint free cloth.
Installation Procedure
1. Install a adhesive sealant bead around the outside (1) of the groove of the upper frame 2 mm
(1/16 in) thick. 2. Install a adhesive sealant bead only along the front (2), on the inside of the
groove 2 mm (1/16 in) thick.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10460
Important: Put the seam of the sunroof window seal in the front under the window holder.
This is done to prevent tension in the seal.
3. Place the new sunroof window seal in the frame without pressure.
4. Install the front center under the window holder and push the sunroof window seal from the sides
to the rear only 1 mm (1/32 in) into the groove.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10461
5. Install the sunroof window seal entirely into the groove, the seal Must be kept flush fitted in the
frame.
6. Remove excessive adhesive sealant from around the sunroof window seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10462
7. The sunroof must remain open until the adhesive sealant is dry.
* Check the curing time on the adhesive sealant.
* If the sunroof window has to be close after repair , it is advisable to apply a strip of masking tape
in the front center over the seal before closing. This is done to prevent the seal from pulling out of
the groove,
* When the repairs are completed and cured, water test the vehicle to ensure no leaks.
8. Verify operations of the sunroof window.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair >
Front Seat Head Restraint Replacement
Head Rest: Service and Repair Front Seat Head Restraint Replacement
Front Seat Head Restraint Replacement
Removal Procedure
1. Raise the head restraint to the full up position by pressing the release tab (2), and by lifting up
the head restraint. 2. Insert a small tool into the head restraint retainer port (1). 3. In order to
release the head restraint retainer, simultaneously lift up on the head restraint while applying
inward pressure to the tool in the retainer
release port (1).
4. Remove the head restraint from the seat assembly.
Installation Procedure
1. Position the head restraint to the seat assembly. 2. Verify that the notches in the head restraint
posts are indexed toward the rear of the seat assembly. 3. Push the head restraint downward into
the fully installed position. 4. Raise the head restraint to the full up position. Verify that the head
restraint retainer prevents the head restraint from being removed from the seat
assembly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair >
Front Seat Head Restraint Replacement > Page 10468
Head Rest: Service and Repair Front Seat Head Restraint Guide Replacement
Front Seat Head Restraint Guide Replacement
Removal Procedure
1. Remove the front seat assembly. Refer to Front Seat Replacement - Bucket (See: Service and
Repair/Front Seat Replacement - Bucket) or Split
Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement).
2. Remove the front seat head restraint. Refer to Front Seat Head Restraint Replacement (See:
Front Seat Head Restraint Replacement). 3. Pull the seat back cover and the seat back pad up
high enough to expose the head restraint guides. Refer to Front Seat Back Cushion Cover and
Cushion Pad Replacement (See: Seat Back/Service and Repair/Front Seat Back Cushion Cover
and Cushion Pad Replacement).
4. Squeeze the retaining tabs located at the bottom of the guides together in order to remove the
guides from the seat frame. 5. Remove the guides from the seat back frame.
Installation Procedure
1. Install the guides to the seat back frame, verifying that the lower retainers are fully seated to the
frame.
2. Install the guide with the locking tab (1) on the seat's right-hand side. 3. Install the seat back
cover and pad. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement (See: Seat
Back/Service and
Repair/Front Seat Back Cushion Cover and Cushion Pad Replacement).
4. Install the front seat head restraint. Refer to Front Seat Head Restraint Replacement (See: Front
Seat Head Restraint Replacement). 5. Install the seat assembly. Refer to Front Seat Replacement
- Bucket (See: Service and Repair/Front Seat Replacement - Bucket) or Split Bench
Seat Replacement (See: Service and Repair/Split Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair >
Front Seat Head Restraint Replacement > Page 10469
Head Rest: Service and Repair Rear Seat Head Restraint Replacement
Rear Seat Head Restraint Replacement
Removal Procedure
1. Raise the head restraint to the full up position by pressing the release tab (2), and by lifting up
the head restraint. 2. Insert a small tool into the head restraint retainer port (1). 3. In order to
release the head restraint retainer, simultaneously lift up on the head restraint while applying
inward pressure to the tool in the retainer
release port (1).
4. Remove the head restraint from the seat assembly.
Installation Procedure
1. Position the head restraint to the seat assembly. 2. Verify that the notches in the head restraint
posts are indexed toward the rear of the seat assembly. 3. Push the head restraint downward into
the fully installed position. 4. Raise the head restraint to the full up position. Verify that the head
restraint retainer prevents the head restraint from being removed from the seat
assembly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical
Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information
Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest
Information
INFORMATION
Bulletin No.: 10-08-50-003A
Date: March 24, 2011
Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom
Upholstery or Other Comfort Enhancing Devices
Models:
2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 10-08-50-003 (Section 08 - Body and Accessories).
Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE
HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS
RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD
RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED
DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE
OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS
INCURRED.
You may have a customer with a concern that the head restraint is uncomfortable or sits too far
forward. The front driver and passenger seats are equipped with head restraints that have been
designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle
has its own specifically designed head restraint.
The head restraints should only be used in the vehicle for which they were designed. The head
restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or
head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or
head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket
comfort enhancing pad or device, is installed.
Never modify the design of the head restraint or remove the head restraint from the vehicle as this
may interfere with the operation of the seating and restraint systems and may prevent proper
positioning of the passenger within the vehicle.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations
Power Seat Motor: Locations
Passenger Compartment/Roof Component Views
Under the Driver Seat Components
1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1)
5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver
Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver
Passenger Seat Components - 2 of 2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 10477
1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence
System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2)
Under the Passenger Seat Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 10478
1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor
(SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger
(KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1)
7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 10479
Power Seat Motor: Diagrams
Component Connector End Views
Seat Adjuster Motor Assembly - Driver (AG1)
Seat Adjuster Motor Assembly - Passenger (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 10480
Seat Lumbar Motor - Driver (AR9)
Seat Lumbar Motor - Passenger (AR9)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 10481
Seat Vertical Motor - Driver (AG1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 10482
Power Seat Motor: Service and Repair
Power Seat Adjuster Mechanism Replacement
Removal Procedure
1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and
Repair/Front Seat Replacement - Bucket) or Split
Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement).
2. Remove the seat back recliner handle. Refer to Driver or Passenger Seat Recliner Handle
Replacement (See: Service and Repair/Driver or
Passenger Seat Recliner Handle Replacement).
3. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel
Replacement (See: Seat Cushion/Service and Repair/Seat
Cushion Outer Trim Panel Replacement).
4. Remove the switch bezel. Refer to Driver or Passenger Seat Adjuster Switch Bezel
Replacement (See: Service and Repair/Driver or Passenger
Seat Adjuster Switch Bezel Replacement).
5. Unclip the front, rear, and side J-strips (1, 2) on the underside of the seat.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 10483
6. Remove the 2 push pins (1) securing the seat cushion spacer (2) to the seat adjuster.
7. Remove the 2 bolts (1) securing the seat recliner to the seat adjuster. 8. Remove the seat back
and recliner assemblies from the seat adjuster.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 10484
9. Disconnect the harness (3) from the seat position sensor (1).
10. Remove the 2 nuts (2) securing the seat position switch (1) to the seat adjuster.
11. Remove the seat harness connectors (2) from the power seat adjuster (1). 12. Remove the
seat harness from the seat adjuster assembly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 10485
13. Disconnect the seat belt buckle electrical connector. 14. Remove the bolt (2) securing the seat
belt buckle assembly (1) to the seat adjuster. 15. Remove the seat cushion cover and foam.
16. Remove the 4 nuts (1) securing the seat cushion frame to the seat adjusters. 17. Remove the
power seat adjuster.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 10486
1. Install the seat cushion spacer (2) to the seat adjuster with the 2 push pins (1).
2. Install the seat harness connectors (2) to the power seat adjuster (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 10487
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the seat position switch (1) to the seat adjuster with 2 nuts (2).
Tighten the seat position switch nuts to 24 Nm (18 lb ft).
4. Connect the wiring harness (3) to the seat position switch (1).
5. Install the power seat adjuster to the seat cushion frame with 4 nuts (1).
Tighten the seat cushion frame mounting nuts to 24 Nm (18 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 10488
6. Install the seat cushion foam pad and cover to the frame. 7. Install the seat belt buckle assembly
(1) through the seat cushion pad. 8. Install the seat belt buckle assembly (1) to the seat adjuster
with the bolt (2).
Tighten the seat belt buckle bolt to 55 Nm (41 lb ft).
9. Connect the seat belt buckle electrical connector (1).
10. Position the seat back assembly on the seat cushion assembly.
11. Install the 2 bolts (1) securing the seat back and recliner assemblies to the seat adjuster.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 10489
12. Install the front, rear, and side J-strips (1, 2) to the underside of the seat. 13. Install the switch
bezel. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and
Repair/Driver or Passenger Seat
Adjuster Switch Bezel Replacement).
14. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement
(See: Seat Cushion/Service and Repair/Seat
Cushion Outer Trim Panel Replacement).
15. Install the seat back recliner handle. Refer to Driver or Passenger Seat Recliner Handle
Replacement (See: Service and Repair/Driver or
Passenger Seat Recliner Handle Replacement).
16. Install the seat in the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and
Repair/Front Seat Replacement - Bucket) or Split
Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations
Power Seat Switch: Locations
Passenger Compartment/Roof Component Views
Under the Driver Seat Components
1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1)
5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver
Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver
Passenger Seat Components - 2 of 2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations >
Page 10493
1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence
System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations >
Page 10494
Power Seat Switch: Diagrams
Component Connector End Views
Seat Adjuster Switch - Driver X1 (AG1)
Seat Adjuster Switch - Driver X2 (AG1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations >
Page 10495
Seat Adjuster Switch - Passenger (AG2)
Seat Lumbar Adjuster Switch - Driver (AG1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations >
Page 10496
Seat Lumbar Adjuster Switch - Passenger (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and
Repair > Power Seat Switch Replacement
Power Seat Switch: Service and Repair Power Seat Switch Replacement
Power Seat Switch Replacement
Removal Procedure
1. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel
Replacement (See: Seat Cushion/Service and Repair/Seat
Cushion Outer Trim Panel Replacement).
2. Remove the switch bezel from the seat assembly. Refer to Driver or Passenger Seat Adjuster
Switch Bezel Replacement (See: Service and
Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
3. Remove the buttons from the switch (2).
4. Release the tabs (1) that retain the seat switch (2) to the seat bezel.
5. Disconnect the power seat switch harness (1) from the seat harness.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and
Repair > Power Seat Switch Replacement > Page 10499
6. Remove the power seat switch from the seat bezel.
Installation Procedure
1. Connect the power seat switch harness (1) to the seat harness.
2. Install the power seat switch (2) to the seat bezel. Verify that the retaining tabs (1) are fully
seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat
assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service
and
Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
5. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement
(See: Seat Cushion/Service and Repair/Seat
Cushion Outer Trim Panel Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and
Repair > Power Seat Switch Replacement > Page 10500
Power Seat Switch: Service and Repair Lumbar Switch Replacement
Lumbar Switch Replacement
Removal Procedure
1. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel
Replacement (See: Seat Cushion/Service and Repair/Seat
Cushion Outer Trim Panel Replacement).
2. Remove the switch bezel from the seat assembly. Refer to Driver or Passenger Seat Adjuster
Switch Bezel Replacement (See: Service and
Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
3. Remove the buttons from the switch (3).
4. Release the tabs (4) that retain the seat switch (3) to the seat bezel.
5. Disconnect the lumbar switch harness (1) from the seat harness.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and
Repair > Power Seat Switch Replacement > Page 10501
6. Remove the lumbar switch from the seat bezel.
Installation Procedure
1. Connect the lumbar switch harness (1) to the seat harness.
2. Install the lumbar switch (3) to the seat bezel. Verify that the retaining tabs (4) are fully seated. 3.
Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Refer to
Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and
Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
5. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement
(See: Seat Cushion/Service and Repair/Seat
Cushion Outer Trim Panel Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement
Seat Back: Service and Repair Front Seat Back Cushion Cover and Cushion Pad Replacement
Front Seat Back Cushion Cover and Cushion Pad Replacement
Removal Procedure
1. Adjust lumbar to a relaxed position. 2. Remove the seat from the vehicle. Refer to Split Bench
Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket).
3. Remove the seat back release handle. Refer to EZ Entry Seat Manual Release Knob
Replacement (See: Service and Repair/EZ Entry Seat Manual
Release Knob Replacement).
4. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel
Replacement (See: Seat Cushion/Service and Repair/Seat
Cushion Outer Trim Panel Replacement).
5. Remove the head restraint. Refer to Front Seat Head Restraint Replacement (See: Head
Rest/Service and Repair/Front Seat Head Restraint
Replacement).
6. Release the J-strip (1) across the bottom of the seat back cover. 7. Compress the seat back pad
in order to relieve the pressure against the seat cover. 8. Using a side to side motion, carefully lift
off the seat back cover, partially separating the seat back cover from the foam pad.
Important: When separating the seat cover hook and loop retaining strips, do not pull the
adhesive-backed strip from the pad.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10506
9. Release the lower Velcro retaining strips (2) located inside the seat cover (1).
10. Remove the hog rings that retain the seat back pad to the reinforcement bar located at the top
of the seat back. 11. Spread the pad apart and push the cover and pad up over the seat back in
order to expose the head restraint guides. 12. Remove the head restraint guides by squeezing the
locking tabs together and pulling the restraint guides upward and out of the seat frame. 13.
Remove the seat back cover the remainder of the way from the seat back. 14. Disconnect the
electrical connector for the seat back heating element, located near the seat belt retractor, if
equipped. 15. Carefully remove the seat back pad from the seat back frame. 16. Remove the seat
back heater element. Refer to Driver or Passenger Seat Back Cushion Heater Replacement (See:
Seat Heater/Service and
Repair/Driver or Passenger Seat Back Cushion Heater Replacement).
Installation Procedure
1. Install the seat back heater element. Refer to Driver or Passenger Seat Back Cushion Heater
Replacement (See: Seat Heater/Service and
Repair/Driver or Passenger Seat Back Cushion Heater Replacement).
2. Position the seat back pad to the seat back frame. 3. Connect the electrical connector to the seat
back heating element, if equipped. 4. Partially install the seat back cover over the top of the seat. 5.
Install the head restraint guides to the seat frame. Ensure that the locking tabs are fully seated. The
guide with the release tab goes on the
right-hand side.
6. Install the hog rings that retain the seat back pad to the reinforcement bar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10507
7. Pull the seat cover (1) over the seat back pad (3). 8. Press the seat cover hook and loop
retaining strips (2) together by firmly running your hand over the seat back cover (1).
9. Install the J-strip (1) across the bottom of the seat back cover.
10. Install the head restraint. Refer to Front Seat Head Restraint Replacement (See: Head
Rest/Service and Repair/Front Seat Head Restraint
Replacement).
11. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement
(See: Seat Cushion/Service and Repair/Seat
Cushion Outer Trim Panel Replacement).
12. Install the seat back release handle. Refer to EZ Entry Seat Manual Release Knob
Replacement (See: Service and Repair/EZ Entry Seat Manual
Release Knob Replacement).
13. Install the seat in the vehicle. Refer to Split Bench Seat Replacement (See: Service and
Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10508
Seat Back: Service and Repair Front Seat Back Frame Replacement
Front Seat Back Frame Replacement
Removal Procedure
1. Remove the seat from the vehicle. Refer to Split Bench Seat Replacement (See: Service and
Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket).
2. Remove the seat back cover and pad. Refer to Front Seat Back Cushion Cover and Cushion
Pad Replacement (See: Front Seat Back Cushion
Cover and Cushion Pad Replacement).
3. Remove the lumbar assembly. Refer to Front Seat Lumbar Support Replacement (See: Service
and Repair/Front Seat Lumbar Support
Replacement).
4. Remove the 4 seat recliner mounting bolts (1) securing the seat back frame to the seat back
recliner mechanism. 5. Remove the seat back frame.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10509
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the seat back frame to the seat back recliner mechanism with 4 bolts (1).
Tighten the front seat recliner bolts to 24 Nm (18 lb ft).
2. Install the lumbar assembly. Refer to Front Seat Lumbar Support Replacement (See: Service
and Repair/Front Seat Lumbar Support Replacement
).
3. Install the seat back pad and cover. Refer to Front Seat Back Cushion Cover and Cushion Pad
Replacement (See: Front Seat Back Cushion Cover
and Cushion Pad Replacement).
4. Install the seat in the vehicle. Refer to Split Bench Seat Replacement (See: Service and
Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10510
Seat Back: Service and Repair Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab)
Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab)
Removal Procedure
1. Remove the rear bench seat from the vehicle. Refer to Rear Bench Seat Replacement (See:
Service and Repair/Rear Bench Seat Replacement). 2. Remove the rear head rest restraints, if
equipped. Refer to Rear Seat Head Restraint Replacement (See: Head Rest/Service and
Repair/Rear Seat
Head Restraint Replacement).
3. Release the J-strip (1) on the bottom edge of the seat back cover. 4. Remove the seat cushion
cover and pad from the seat frame. 5. Remove the hog rings securing the cover to the pad.
Installation Procedure
1. Install the hog rings securing the cover to the pad. 2. Install the seat cushion cover and pad over
the seat frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10511
3. Install the J-strip (1) on the cover. 4. Install the rear head rest restraints, if equipped. Refer to
Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat
Head Restraint Replacement).
5. Install the rear bench seat in the vehicle. Refer to Rear Bench Seat Replacement (See: Service
and Repair/Rear Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10512
Seat Back: Service and Repair Rear Seat Back Cushion Frame Replacement (Crew Cab)
Rear Seat Back Cushion Frame Replacement (Crew Cab)
Removal Procedure
1. Remove the seat from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and
Repair/Rear Bench Seat Replacement). 2. Remove the rear head rest restraints, if equipped. Refer
to Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat
Head Restraint Replacement).
3. Remove the screw securing the side trim covers to the seat cushion frame. 4. Remove the seat
back cover and pad. Refer to Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab)
(See: Rear Seat Back Cushion
Cover and Pad Replacement (Crew Cab)).
5. Remove the head restraint guides from the seat back frame by pinching the tabs on the guides
and pulling the guides out of the frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10513
6. Remove the seat back latch assembly. Refer to Rear Seat Back Latch Replacement (See: Seat
Latch/Service and Repair).
7. Remove the bolt securing the seat back frame to the seat cushion frame.
8. Remove the seat back frame by pulling the frame off the seat cushion frame stud. 9. Inspect the
white nylon bushing on the seat back frame for wear or damage and replace if necessary.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10514
1. Install the seat back frame by pushing the frame onto the seat cushion frame stud.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt securing the seat back frame to the seat cushion frame.
Tighten the rear bench seat back frame mounting bolt to 50 Nm (37 lb ft).
3. Install the seat back latch assembly. Refer to Rear Seat Back Latch Replacement (See: Seat
Latch/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10515
4. Install the head restraint guides in the seat back frame by pushing the guides through the frame
until the tabs lock into place. 5. Install the seat back cover and pad. Refer to Rear Seat Back
Cushion Cover and Pad Replacement (Crew Cab) (See: Rear Seat Back Cushion
Cover and Pad Replacement (Crew Cab)).
6. Install the screw securing the side trim covers to the seat cushion frame.
Tighten the rear bench seat side trim cover screw to 1.5 Nm (13 lb in).
7. Install the rear head rest restraints, if equipped. Refer to Rear Seat Head Restraint Replacement
(See: Head Rest/Service and Repair/Rear Seat
Head Restraint Replacement).
8. Install the seat from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and
Repair/Rear Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10516
Seat Back: Service and Repair
Front Seat Back Cushion Cover and Cushion Pad Replacement
Front Seat Back Cushion Cover and Cushion Pad Replacement
Removal Procedure
1. Adjust lumbar to a relaxed position. 2. Remove the seat from the vehicle. Refer to Split Bench
Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket).
3. Remove the seat back release handle. Refer to EZ Entry Seat Manual Release Knob
Replacement (See: Service and Repair/EZ Entry Seat Manual
Release Knob Replacement).
4. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel
Replacement (See: Seat Cushion/Service and Repair/Seat
Cushion Outer Trim Panel Replacement).
5. Remove the head restraint. Refer to Front Seat Head Restraint Replacement (See: Head
Rest/Service and Repair/Front Seat Head Restraint
Replacement).
6. Release the J-strip (1) across the bottom of the seat back cover. 7. Compress the seat back pad
in order to relieve the pressure against the seat cover. 8. Using a side to side motion, carefully lift
off the seat back cover, partially separating the seat back cover from the foam pad.
Important: When separating the seat cover hook and loop retaining strips, do not pull the
adhesive-backed strip from the pad.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10517
9. Release the lower Velcro retaining strips (2) located inside the seat cover (1).
10. Remove the hog rings that retain the seat back pad to the reinforcement bar located at the top
of the seat back. 11. Spread the pad apart and push the cover and pad up over the seat back in
order to expose the head restraint guides. 12. Remove the head restraint guides by squeezing the
locking tabs together and pulling the restraint guides upward and out of the seat frame. 13.
Remove the seat back cover the remainder of the way from the seat back. 14. Disconnect the
electrical connector for the seat back heating element, located near the seat belt retractor, if
equipped. 15. Carefully remove the seat back pad from the seat back frame. 16. Remove the seat
back heater element. Refer to Driver or Passenger Seat Back Cushion Heater Replacement (See:
Seat Heater/Service and
Repair/Driver or Passenger Seat Back Cushion Heater Replacement).
Installation Procedure
1. Install the seat back heater element. Refer to Driver or Passenger Seat Back Cushion Heater
Replacement (See: Seat Heater/Service and
Repair/Driver or Passenger Seat Back Cushion Heater Replacement).
2. Position the seat back pad to the seat back frame. 3. Connect the electrical connector to the seat
back heating element, if equipped. 4. Partially install the seat back cover over the top of the seat. 5.
Install the head restraint guides to the seat frame. Ensure that the locking tabs are fully seated. The
guide with the release tab goes on the
right-hand side.
6. Install the hog rings that retain the seat back pad to the reinforcement bar.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10518
7. Pull the seat cover (1) over the seat back pad (3). 8. Press the seat cover hook and loop
retaining strips (2) together by firmly running your hand over the seat back cover (1).
9. Install the J-strip (1) across the bottom of the seat back cover.
10. Install the head restraint. Refer to Front Seat Head Restraint Replacement (See: Head
Rest/Service and Repair/Front Seat Head Restraint
Replacement).
11. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement
(See: Seat Cushion/Service and Repair/Seat
Cushion Outer Trim Panel Replacement).
12. Install the seat back release handle. Refer to EZ Entry Seat Manual Release Knob
Replacement (See: Service and Repair/EZ Entry Seat Manual
Release Knob Replacement).
13. Install the seat in the vehicle. Refer to Split Bench Seat Replacement (See: Service and
Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket).
Front Seat Back Frame Replacement
Front Seat Back Frame Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10519
Removal Procedure
1. Remove the seat from the vehicle. Refer to Split Bench Seat Replacement (See: Service and
Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket).
2. Remove the seat back cover and pad. Refer to Front Seat Back Cushion Cover and Cushion
Pad Replacement (See: Front Seat Back Cushion
Cover and Cushion Pad Replacement).
3. Remove the lumbar assembly. Refer to Front Seat Lumbar Support Replacement (See: Service
and Repair/Front Seat Lumbar Support
Replacement).
4. Remove the 4 seat recliner mounting bolts (1) securing the seat back frame to the seat back
recliner mechanism. 5. Remove the seat back frame.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10520
1. Install the seat back frame to the seat back recliner mechanism with 4 bolts (1).
Tighten the front seat recliner bolts to 24 Nm (18 lb ft).
2. Install the lumbar assembly. Refer to Front Seat Lumbar Support Replacement (See: Service
and Repair/Front Seat Lumbar Support Replacement
).
3. Install the seat back pad and cover. Refer to Front Seat Back Cushion Cover and Cushion Pad
Replacement (See: Front Seat Back Cushion Cover
and Cushion Pad Replacement).
4. Install the seat in the vehicle. Refer to Split Bench Seat Replacement (See: Service and
Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket).
Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab)
Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab)
Removal Procedure
1. Remove the rear bench seat from the vehicle. Refer to Rear Bench Seat Replacement (See:
Service and Repair/Rear Bench Seat Replacement). 2. Remove the rear head rest restraints, if
equipped. Refer to Rear Seat Head Restraint Replacement (See: Head Rest/Service and
Repair/Rear Seat
Head Restraint Replacement).
3. Release the J-strip (1) on the bottom edge of the seat back cover. 4. Remove the seat cushion
cover and pad from the seat frame. 5. Remove the hog rings securing the cover to the pad.
Installation Procedure
1. Install the hog rings securing the cover to the pad. 2. Install the seat cushion cover and pad over
the seat frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10521
3. Install the J-strip (1) on the cover. 4. Install the rear head rest restraints, if equipped. Refer to
Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat
Head Restraint Replacement).
5. Install the rear bench seat in the vehicle. Refer to Rear Bench Seat Replacement (See: Service
and Repair/Rear Bench Seat Replacement).
Rear Seat Back Cushion Frame Replacement (Crew Cab)
Rear Seat Back Cushion Frame Replacement (Crew Cab)
Removal Procedure
1. Remove the seat from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and
Repair/Rear Bench Seat Replacement). 2. Remove the rear head rest restraints, if equipped. Refer
to Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat
Head Restraint Replacement).
3. Remove the screw securing the side trim covers to the seat cushion frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10522
4. Remove the seat back cover and pad. Refer to Rear Seat Back Cushion Cover and Pad
Replacement (Crew Cab) (See: Rear Seat Back Cushion
Cover and Pad Replacement (Crew Cab)).
5. Remove the head restraint guides from the seat back frame by pinching the tabs on the guides
and pulling the guides out of the frame. 6. Remove the seat back latch assembly. Refer to Rear
Seat Back Latch Replacement (See: Seat Latch/Service and Repair).
7. Remove the bolt securing the seat back frame to the seat cushion frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10523
8. Remove the seat back frame by pulling the frame off the seat cushion frame stud. 9. Inspect the
white nylon bushing on the seat back frame for wear or damage and replace if necessary.
Installation Procedure
1. Install the seat back frame by pushing the frame onto the seat cushion frame stud.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10524
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt securing the seat back frame to the seat cushion frame.
Tighten the rear bench seat back frame mounting bolt to 50 Nm (37 lb ft).
3. Install the seat back latch assembly. Refer to Rear Seat Back Latch Replacement (See: Seat
Latch/Service and Repair).
4. Install the head restraint guides in the seat back frame by pushing the guides through the frame
until the tabs lock into place. 5. Install the seat back cover and pad. Refer to Rear Seat Back
Cushion Cover and Pad Replacement (Crew Cab) (See: Rear Seat Back Cushion
Cover and Pad Replacement (Crew Cab)).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10525
6. Install the screw securing the side trim covers to the seat cushion frame.
Tighten the rear bench seat side trim cover screw to 1.5 Nm (13 lb in).
7. Install the rear head rest restraints, if equipped. Refer to Rear Seat Head Restraint Replacement
(See: Head Rest/Service and Repair/Rear Seat
Head Restraint Replacement).
8. Install the seat from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and
Repair/Rear Bench Seat Replacement).
Rear Seat Back Cushion Frame Replacement (Extended Cab)
Rear Seat Back Cushion Frame Replacement (Extended Cab)
Removal Procedure
1. Remove the rear seat back from the vehicle by grasping the back and lifting straight up.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10526
2. Remove the hog rings (1) from the cover (2). 3. Remove the seat back cover from the seat back
frame/pad.
Installation Procedure
1. Install the seat back cover over the seat back frame/pad.
2. Install the hog rings (1) on the cover (2). 3. Install the rear seat back in the vehicle by aligning
the hooks in the slots and pushing the seat back downward.
Driver or Passenger Seat Back Cushion Finish Panel Replacement
Driver or Passenger Seat Back Cushion Finish Panel Replacement
Removal Procedure
1. Remove the seat from the vehicle. Refer to Split Bench Seat Replacement (See: Service and
Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket).
2. Remove the front seat back cover and pad. Refer to Front Seat Back Cushion Cover and
Cushion Pad Replacement (See: Front Seat Back
Cushion Cover and Cushion Pad Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10527
3. Remove the 2 hog ring fasteners (3) on the bottom of the seat back panel (2). 4. Remove the
push-pin fastener (1) from the top of the seat back panel. 5. Remove the seat-back panel.
Installation Procedure
1. Position the seat back panel on the seat-back frame. 2. Install the seat back panel to the frame
with a push-pin fastener (1) at the top of the panel.
3. Install the 2 hog ring fasteners (3) to the bottom of the seat back panel (2). 4. Install the front
seat back cover and pad. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement
(See: Front Seat Back Cushion
Cover and Cushion Pad Replacement).
5. Install the seat in the vehicle. Refer to Split Bench Seat Replacement (See: Service and
Repair/Split Bench Seat Replacement) or Front Seat
Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket).
Rear Seat Back Cushion Replacement (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10528
Rear Seat Back Cushion Replacement (Crew Cab)
Removal Procedure
1. Release the rear seat back latches.
2. Remove the screw securing the side trim covers to the seat cushion frame.
3. Remove the bolt securing the seat back frame to the seat cushion frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10529
4. Remove the seat back frame by pulling the frame off the seat cushion frame stud. 5. Inspect the
white nylon bushing on the seat back frame for wear or damage and replace if necessary.
Installation Procedure
1. Install the seat back frame by pushing the frame onto the seat cushion frame stud.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10530
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolt securing the seat back frame to the seat cushion frame.
Tighten the seat back frame mounting bolt to 50 Nm (37 lb ft).
3. Install the screw securing the side trim covers to the seat cushion frame.
Rear Seat Back Cushion Replacement (Extended Cab)
Rear Seat Back Cushion Replacement (Extended Cab)
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10531
1. Remove the rear seat back from the vehicle by grasping the back and lifting straight up. 2.
Remove the rear seat back from the vehicle.
Installation Procedure
1. Position the rear seat back by aligning the hooks with the slots in the vehicle. 2. Install the rear
seat back by pushing the seat back downward.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info
Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info
INFORMATION
Bulletin No.: 04-08-50-006D
Date: September 09, 2010
Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and
Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and
Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin
Number 04-08-50-006C (Section 08 - Body and Accessories).
If a customer comes in to your dealership due to certain conditions of the seat covers (splits,
wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of
the customer claim. Some components from the above listed vehicles have been returned to the
Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or
No Trouble Found (NTF).
The dealer should pay particular attention to the following conditions:
- Cigarette burns
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10536
- Customer induced cuts (knife cuts, cut by customer tools, etc.)
- Paint stains (customer should have cleaned paint stains while paint was still wet)
- Coffee stains and other removable dirt These should be cleaned as described in the Owner's
Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later.
- Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual
- Other chemical spills
- Minor and normal leather wrinkles as a result of use
- Other defects to the seat cover not detected during the pre-delivery inspection (PDI).
Inform the customer that the above issues were not present when the vehicle was purchased and
cannot be replaced under warranty. The covers, however, may be repaired or replaced at the
customer's expense.
The following conditions are not caused by the customer and should be covered by warranty:
- Split seams
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10537
- Wear/cracking/peeling
- Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed
after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409),
replace the covers.)
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10538
Seat Cover: Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle
INFORMATION
Bulletin No.: 06-00-89-029F
Date: April 27, 2010
Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather,
Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability
Models:
2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum
and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009
Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 06-00-89-029E (Section 00 - General Information).
To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the
upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which
can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care
should be taken because newspapers and garments may transfer color to the vehicle's interior.
Many of today's interiors are made with new low gloss materials. Permanent damage may result
from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and
fabric) for which they are not intended. Using non-approved products can actually set the stain to
the point that nothing can remove it.
Important
Do not use silicone or wax-based products or those containing organic solvents (such as naptha,
alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing
the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the
windshield and even make it difficult to see through the windshield under certain conditions.
- Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This
can cause damage to the vehicle's interior surfaces.
- Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with
degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt.
Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of
the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are
in the neutral-pH range and will maintain the best vehicle interior appearance. These products are
water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals.
Interior trim pieces on new vehicles, as well as service components, arrive with a protective film.
When removing the protective film, adhesive residue may be left on the trim panels/components.
The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing
adhesive residue without causing damage to the component.
Important
- If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the
residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the
pH neutral range, they won't leave behind soapy residue.
- On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be
treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this
bulletin for more information.
Effective cleaning steps for hard and/or plastic surfaces:
1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the
towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work
cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the
surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the
towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's
original luster.
Important Today's interiors are developed and intended to have a low-gloss appearance. It is
important to use only products which provide a low-gloss finish in order to maintain the interior's
integrity, customer appeal and satisfaction.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10539
Effective cleaning steps for fabric:
1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate
stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle
brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to
reduce or eliminate future staining.
Upholstery and Carpet Stains
When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you
determine which cleaner/formula works best on a particular stain. The chart lists many of the
common stains. Some complex stains may require the application of both stain removers, one after
the other, to remove both food-based oils and synthetic oils.
A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain
or material. This enables the dirt/stain to be completely removed from the material.
Leather Conditioner/Restorer
A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a
water-based product and contains essential emollients to restore suppleness, conditions and adds
luster without adding gloss. The restorer will also provide protection against re-staining.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10540
Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede
comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will
appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely
affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with
the restorer.
Extractor Machine and Concentrate
For difficult to clean materials or when cleaning a large area, the best results will be achieved when
using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N
627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released
a concentrate for use with the extractor machine.
Whichever extractor machine is used, it should meet the minimum specifications of the Ruby
Extractor:
Ruby Extractor Specifications:
- Pump PSI: 55
- Water Lift: 85"
- Hose Length: 10 ft
Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty.
Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in
the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The
water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry
time is greatly reduced due to less water on the fabric surface, the vacuum head making better
contact with the surface and the significant water lift capability of the machine.
Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help
remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions
listed on the container. The available concentrate helps to break the stain down and then the stain
is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to
remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions.
Dirt, grease and grime are more easily removed when the proper solution is used during the
extraction process.
Parts Information
Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles.
Available Equipment
Equipment is available by contacting 1-800-GMTOOLS.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10541
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10542
Seat Cover: Technical Service Bulletins Interior - Elimination Of Unwanted Odors
INFORMATION
Bulletin No.: 00-00-89-027E
Date: September 29, 2008
Subject: Eliminating Unwanted Odors in Vehicles
Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior
HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X
Supercede:
This bulletin is being revised to add model years and refine the instructions. Please discard
Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information).
Vehicle Odor Elimination
General Motors offers a product that may control or eliminate odors in the interior and luggage
compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic,
biodegradable odor remover. This odorless product has been shown to greatly reduce or remove
objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer
created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl,
leather, carpet and sound deadening materials. It may also be induced into HVAC modules and
instrument panel ducts (for the control of non-bacterial related odors).
Important:
This product leaves no residual scent and should not be sold as or considered an air freshener.
Product action may result in the permanent elimination of an odor and may be preferable to
customers with allergies who are sensitive to perfumes.
How to Use This Product
GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam
cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all
vehicle interiors. Do not wet or soak any interior surface that plain water would cause to
deteriorate, as this product will have the same effect. Also avoid letting this product come into
contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of,
or render GM Vehicle Care Odor Eliminator inert.
Note:
Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor
Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by
step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a
replacement set faxed or e-mailed to your dealership.
Instructions and cautions are printed on the bottle, but additional help is available. If you encounter
a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada,
1-800-977-4145) to obtain additional information and usage suggestions.
Important:
This product may effectively remove odors when directly contacting the odor source. It should be
used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the
root cause of the odor, and then the residual odor to permanently correct the vehicle condition.
Vehicle Waterleak Odor Elimination
STEP ONE:
Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water
soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor
source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle
interior by careful evaluation. Odor evaluation may need to be performed by multiple persons.
Another method of isolating an odor source is to remove and segregate interior trim and
components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist
in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated
separately to determine if the odor stays with the vehicle or the interior components. Odors that
stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak
at the windshield or standing water in the front foot well area caused mold/mildew to form on the
bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and
primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and
dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product
before reinstalling carpet or reassembling.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10543
The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used
properly. It must come into direct contact with the odor source. It should be used in conjunction with
diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after
odor root cause correction are:
STEP TWO:
^ Use the trigger spray head.
^ Put a drop of dish soap the size of a quarter in the bottom of a bottle.
^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with
tap water.
^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan)
STEP THREE:
The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and
upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting
(at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The
headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and
upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should
be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface.
STEP FOUR: (vehicle ventilation system treatment)
The ventilation system is generally the last step in the treatment of the vehicle.
a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per
vent).
b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting).
c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of
windshield)
d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents.
e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into
the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell
coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray
3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7
minutes.
Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited
is resolved without completing every step, the remaining steps do not need to be performed. If
these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.
Additional Suggestions to Increase Customer Satisfaction
Here are some additional ideas to benefit your dealership and to generate greater customer
enthusiasm for this product.
^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to
your used car trades; treat loaner and demo cars during service and at final sale to eliminate
smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of
your normal vehicle detailing service.
^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle
purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM
Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the
vehicle. Customers may find this product can be used for a host of recreational activities
associated with their new vehicle, such as deodorizing a boat they tow, or a camper.
^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase
dealership traffic as these superior quality products cannot be purchased in stores. Many
Dealerships have product displays at the parts counter. Consider additional displays in the
Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many
customers who purchase vehicles and receive regular maintenance at your dealership may never
visit the parts counter, and subsequently are not exposed to the variety and value that these
products offer.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10544
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement
Seat Cushion: Service and Repair Front Seat Cushion Frame Replacement
Front Seat Cushion Frame Replacement
Removal Procedure
1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and
Repair/Front Seat Replacement - Bucket) or Split
Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement).
2. Remove the cupholder from the seat by pulling it straight off the bracket. 3. Remove the front
seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat
Cushion Outer Trim Panel
Replacement).
4. Remove the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10549
5. Unclip the front, rear, and side J-strips (1, 2) on the underside of the seat. 6. Remove the lumbar
knob by pulling the knob straight away from the seat, if equipped. 7. Remove the seat switch bezel,
if equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service
and
Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
8. Remove the recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement
(See: Service and Repair/Driver or Passenger Seat
Recliner Handle Replacement).
9. Remove the screws (2) that retain the lumbar adjustment mechanism (1) to the seat adjuster.
10. Remove the lumbar cable from the lumbar adjustment mechanism.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Front Seat Cushion Frame Replacement > Page 10550
11. Remove the 2 bolts (1) securing the seat recliner to the seat adjuster. 12. Remove the seat
back assembly from the seat cushion assembly.
13. Disconnect the seat belt buckle electrical connector (1). 14. Remove any clips or straps
securing the electrical harness to the bottom of the seat cushion frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10551
15. Remove the bolt (2) securing the seat belt buckle assembly (1) to the seat adjuster. 16.
Remove the seat cushion cover and foam. 17. Remove the assist spring.
18. Disconnect the wire harness for the lumbar and seat heat switches and pull the harness (2)
back through the hole in the seat cushion frame. 19. Remove the 4 nuts (1) securing the seat
cushion frame to the seat adjuster. 20. Remove the seat cushion frame.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10552
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the seat cushion frame to the seat adjuster with 4 nuts (1).
Tighten the front seat cushion frame mounting nuts to 24 Nm (18 lb ft).
2. Route the wire harness for the lumbar and seat heat switches through the hole in the seat
cushion frame and connect the connectors. 3. Install the assist spring.
4. Install the seat cushion foam pad and cover to the frame. 5. Install the seat belt buckle assembly
(1) through the seat cushion pad. 6. Install the seat belt buckle assembly (1) to the seat adjuster
with the bolt (2).
Tighten the front seat belt buckle bolt to 55 Nm (41 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10553
7. Connect the seat belt buckle electrical connector (1). 8. Install any clips or straps securing the
electrical harness to the bottom of the seat cushion frame. 9. Position the seat back assembly on
the seat cushion assembly.
10. Install the 2 bolts (1) securing the seat recliner to the seat adjuster.
Tighten the front seat recliner bolts to 24 Nm (18 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10554
11. Install the lumbar adjustment mechanism (1) to the seat adjuster with the 2 screws (2). 12.
Install the lumbar cable to the lumbar adjustment mechanism. 13. Install the seat switch bezel, if
equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service
and Repair/Driver
or Passenger Seat Adjuster Switch Bezel Replacement).
14. Install the lumbar knob by pushing the knob straight onto the shaft, if equipped. 15. Install the
recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service
and Repair/Driver or Passenger Seat
Recliner Handle Replacement).
16. Install the front, rear, and side J-strips (1, 2) to the underside of the seat.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10555
17. Install the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped.
Tighten the front seat cupholder bracket bolts to 9.1 Nm (80 lb in).
18. Install the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel
Replacement (See: Seat Cushion Outer Trim Panel
Replacement).
19. Install the cupholder to the seat by pushing it straight onto the bracket. 20. Install the seat in the
vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat
Replacement - Bucket) or Split
Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10556
Seat Cushion: Service and Repair Front Seat Cushion Cover and Pad Replacement
Front Seat Cushion Cover and Pad Replacement
Removal Procedure
1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and
Repair/Front Seat Replacement - Bucket) or Split
Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement).
2. Remove the cupholder from the seat by pulling it straight off the bracket. 3. Remove the front
seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat
Cushion Outer Trim Panel
Replacement).
4. Remove the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10557
5. Unclip the front, rear, and side J-strips (1, 2) on the underside of the seat. 6. Remove the lumbar
knob by pulling the knob straight away from the seat, if equipped. 7. Remove the seat switch bezel,
if equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service
and
Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
8. Remove the recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement
(See: Service and Repair/Driver or Passenger Seat
Recliner Handle Replacement).
9. Remove the 2 bolts (1) securing the seat recliner to the seat adjuster.
10. Remove the seat back assembly from the seat cushion assembly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10558
11. Disconnect the seat belt buckle electrical connector (1). 12. Remove any clips or straps
securing the electrical harness to the bottom of the seat cushion frame.
13. Remove the bolt (2) securing the seat belt buckle assembly (1) to the seat adjuster. 14.
Remove the seat cushion cover and foam.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10559
15. Remove the hog rings (3) securing the cover (1) to the pad (2).
16. If the pad is being replaced, peel the heating element (3) off of the pad (2), if equipped.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10560
1. If the pad is being replaced, stick the adhesive-backed heating element (3) onto the pad (2), if
equipped.
2. Install the cover (1) to the pad (2) with the hog rings (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10561
3. Install the seat cushion foam pad and cover to the frame. 4. Install the seat belt buckle assembly
(1) through the seat cushion pad.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Install the seat belt buckle assembly (1) to the seat adjuster with the bolt (2).
Tighten the front seat belt buckle bolt to 55 Nm (41 lb ft).
6. Connect the seat belt buckle electrical connector (1). 7. Install any clips or straps securing the
electrical harness to the bottom of the seat cushion frame. 8. Position the seat back assembly on
the seat cushion assembly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10562
9. Install the 2 bolts (1) securing the seat recliner to the seat adjuster.
Tighten the front seat recliner bolts to 24 Nm (18 lb ft).
10. Install the seat switch bezel, if equipped. Refer to Driver or Passenger Seat Adjuster Switch
Bezel Replacement (See: Service and Repair/Driver
or Passenger Seat Adjuster Switch Bezel Replacement).
11. Install the lumbar knob by pushing the knob straight onto the shaft, if equipped. 12. Install the
recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service
and Repair/Driver or Passenger Seat
Recliner Handle Replacement).
13. Install the front, rear, and side J-strips (1, 2) to the underside of the seat.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10563
14. Install the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped.
Tighten the front seat cupholder bracket bolts to 9.1 Nm (80 lb in).
15. Install the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel
Replacement (See: Seat Cushion Outer Trim Panel
Replacement).
16. Install the cupholder to the seat by pushing it straight onto the bracket. 17. Install the seat in the
vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat
Replacement - Bucket) or Split
Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10564
Seat Cushion: Service and Repair Rear Seat Cushion Cover and Pad Replacement (Crew Cab)
Rear Seat Cushion Cover and Pad Replacement (Crew Cab)
Removal Procedure
1. Remove the rear bench seat from the vehicle. Refer to Rear Bench Seat Replacement (See:
Service and Repair/Rear Bench Seat Replacement). 2. Remove the seat belt buckles (1) from the
seat cover loops (2).
3. Release the J-strips (1) on the cover. 4. Remove the seat cushion cover and pad from the seat
frame (2).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10565
1. Install the seat cushion cover and pad over the seat frame (2). 2. Install the J-strips (1) on the
cover.
3. Install the seat belt buckles (1) through the seat cover loops (2). 4. Install the rear bench seat in
the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10566
Seat Cushion: Service and Repair Rear Seat Cushion Cover and Pad Replacement (Extended
Cab)
Rear Seat Cushion Cover and Pad Replacement (Extended Cab)
Removal Procedure
1. Remove the rear folding seat cushion from the vehicle. Refer to Folding Seat Replacement
(Extended Cab) (See: Service and Repair/Folding Seat
Replacement (Extended Cab)).
2. Release the J-strips (2) on the cover (1). 3. Remove the seat cushion cover from the seat
frame/pad.
Installation Procedure
1. Install the seat cushion cover over the seat frame/pad. 2. Install the J-strips (2) on the cover (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10567
3. Install the rear folding seat cushion in the vehicle. Refer to Folding Seat Replacement (Extended
Cab) (See: Service and Repair/Folding Seat
Replacement (Extended Cab)).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10568
Seat Cushion: Service and Repair
Front Seat Cushion Frame Replacement
Front Seat Cushion Frame Replacement
Removal Procedure
1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and
Repair/Front Seat Replacement - Bucket) or Split
Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement).
2. Remove the cupholder from the seat by pulling it straight off the bracket. 3. Remove the front
seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat
Cushion Outer Trim Panel
Replacement).
4. Remove the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10569
5. Unclip the front, rear, and side J-strips (1, 2) on the underside of the seat. 6. Remove the lumbar
knob by pulling the knob straight away from the seat, if equipped. 7. Remove the seat switch bezel,
if equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service
and
Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
8. Remove the recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement
(See: Service and Repair/Driver or Passenger Seat
Recliner Handle Replacement).
9. Remove the screws (2) that retain the lumbar adjustment mechanism (1) to the seat adjuster.
10. Remove the lumbar cable from the lumbar adjustment mechanism.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10570
11. Remove the 2 bolts (1) securing the seat recliner to the seat adjuster. 12. Remove the seat
back assembly from the seat cushion assembly.
13. Disconnect the seat belt buckle electrical connector (1). 14. Remove any clips or straps
securing the electrical harness to the bottom of the seat cushion frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10571
15. Remove the bolt (2) securing the seat belt buckle assembly (1) to the seat adjuster. 16.
Remove the seat cushion cover and foam. 17. Remove the assist spring.
18. Disconnect the wire harness for the lumbar and seat heat switches and pull the harness (2)
back through the hole in the seat cushion frame. 19. Remove the 4 nuts (1) securing the seat
cushion frame to the seat adjuster. 20. Remove the seat cushion frame.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10572
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Install the seat cushion frame to the seat adjuster with 4 nuts (1).
Tighten the front seat cushion frame mounting nuts to 24 Nm (18 lb ft).
2. Route the wire harness for the lumbar and seat heat switches through the hole in the seat
cushion frame and connect the connectors. 3. Install the assist spring.
4. Install the seat cushion foam pad and cover to the frame. 5. Install the seat belt buckle assembly
(1) through the seat cushion pad. 6. Install the seat belt buckle assembly (1) to the seat adjuster
with the bolt (2).
Tighten the front seat belt buckle bolt to 55 Nm (41 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10573
7. Connect the seat belt buckle electrical connector (1). 8. Install any clips or straps securing the
electrical harness to the bottom of the seat cushion frame. 9. Position the seat back assembly on
the seat cushion assembly.
10. Install the 2 bolts (1) securing the seat recliner to the seat adjuster.
Tighten the front seat recliner bolts to 24 Nm (18 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10574
11. Install the lumbar adjustment mechanism (1) to the seat adjuster with the 2 screws (2). 12.
Install the lumbar cable to the lumbar adjustment mechanism. 13. Install the seat switch bezel, if
equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service
and Repair/Driver
or Passenger Seat Adjuster Switch Bezel Replacement).
14. Install the lumbar knob by pushing the knob straight onto the shaft, if equipped. 15. Install the
recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service
and Repair/Driver or Passenger Seat
Recliner Handle Replacement).
16. Install the front, rear, and side J-strips (1, 2) to the underside of the seat.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10575
17. Install the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped.
Tighten the front seat cupholder bracket bolts to 9.1 Nm (80 lb in).
18. Install the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel
Replacement (See: Seat Cushion Outer Trim Panel
Replacement).
19. Install the cupholder to the seat by pushing it straight onto the bracket. 20. Install the seat in the
vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat
Replacement - Bucket) or Split
Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement).
Front Seat Cushion Cover and Pad Replacement
Front Seat Cushion Cover and Pad Replacement
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10576
1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and
Repair/Front Seat Replacement - Bucket) or Split
Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement).
2. Remove the cupholder from the seat by pulling it straight off the bracket. 3. Remove the front
seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat
Cushion Outer Trim Panel
Replacement).
4. Remove the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10577
5. Unclip the front, rear, and side J-strips (1, 2) on the underside of the seat. 6. Remove the lumbar
knob by pulling the knob straight away from the seat, if equipped. 7. Remove the seat switch bezel,
if equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service
and
Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
8. Remove the recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement
(See: Service and Repair/Driver or Passenger Seat
Recliner Handle Replacement).
9. Remove the 2 bolts (1) securing the seat recliner to the seat adjuster.
10. Remove the seat back assembly from the seat cushion assembly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10578
11. Disconnect the seat belt buckle electrical connector (1). 12. Remove any clips or straps
securing the electrical harness to the bottom of the seat cushion frame.
13. Remove the bolt (2) securing the seat belt buckle assembly (1) to the seat adjuster. 14.
Remove the seat cushion cover and foam.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10579
15. Remove the hog rings (3) securing the cover (1) to the pad (2).
16. If the pad is being replaced, peel the heating element (3) off of the pad (2), if equipped.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10580
1. If the pad is being replaced, stick the adhesive-backed heating element (3) onto the pad (2), if
equipped.
2. Install the cover (1) to the pad (2) with the hog rings (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10581
3. Install the seat cushion foam pad and cover to the frame. 4. Install the seat belt buckle assembly
(1) through the seat cushion pad.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
5. Install the seat belt buckle assembly (1) to the seat adjuster with the bolt (2).
Tighten the front seat belt buckle bolt to 55 Nm (41 lb ft).
6. Connect the seat belt buckle electrical connector (1). 7. Install any clips or straps securing the
electrical harness to the bottom of the seat cushion frame. 8. Position the seat back assembly on
the seat cushion assembly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10582
9. Install the 2 bolts (1) securing the seat recliner to the seat adjuster.
Tighten the front seat recliner bolts to 24 Nm (18 lb ft).
10. Install the seat switch bezel, if equipped. Refer to Driver or Passenger Seat Adjuster Switch
Bezel Replacement (See: Service and Repair/Driver
or Passenger Seat Adjuster Switch Bezel Replacement).
11. Install the lumbar knob by pushing the knob straight onto the shaft, if equipped. 12. Install the
recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service
and Repair/Driver or Passenger Seat
Recliner Handle Replacement).
13. Install the front, rear, and side J-strips (1, 2) to the underside of the seat.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10583
14. Install the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped.
Tighten the front seat cupholder bracket bolts to 9.1 Nm (80 lb in).
15. Install the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel
Replacement (See: Seat Cushion Outer Trim Panel
Replacement).
16. Install the cupholder to the seat by pushing it straight onto the bracket. 17. Install the seat in the
vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat
Replacement - Bucket) or Split
Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement).
Rear Seat Cushion Cover and Pad Replacement (Crew Cab)
Rear Seat Cushion Cover and Pad Replacement (Crew Cab)
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10584
1. Remove the rear bench seat from the vehicle. Refer to Rear Bench Seat Replacement (See:
Service and Repair/Rear Bench Seat Replacement). 2. Remove the seat belt buckles (1) from the
seat cover loops (2).
3. Release the J-strips (1) on the cover. 4. Remove the seat cushion cover and pad from the seat
frame (2).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10585
1. Install the seat cushion cover and pad over the seat frame (2). 2. Install the J-strips (1) on the
cover.
3. Install the seat belt buckles (1) through the seat cover loops (2). 4. Install the rear bench seat in
the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat
Replacement).
Rear Seat Cushion Cover and Pad Replacement (Extended Cab)
Rear Seat Cushion Cover and Pad Replacement (Extended Cab)
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10586
1. Remove the rear folding seat cushion from the vehicle. Refer to Folding Seat Replacement
(Extended Cab) (See: Service and Repair/Folding Seat
Replacement (Extended Cab)).
2. Release the J-strips (2) on the cover (1). 3. Remove the seat cushion cover from the seat
frame/pad.
Installation Procedure
1. Install the seat cushion cover over the seat frame/pad. 2. Install the J-strips (2) on the cover (1).
3. Install the rear folding seat cushion in the vehicle. Refer to Folding Seat Replacement (Extended
Cab) (See: Service and Repair/Folding Seat
Replacement (Extended Cab)).
Rear Seat Cushion Frame Replacement (Crew Cab)
Rear Seat Cushion Frame Replacement (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10587
Removal Procedure
1. Remove the rear bench seat cushion from the vehicle. Refer to Rear Bench Seat Replacement
(See: Service and Repair/Rear Bench Seat
Replacement).
2. Remove the rear cupholder. Refer to Rear Seat Cup Holder Replacement (Crew Cab) (See:
Service and Repair/Rear Seat Cup Holder
Replacement (Crew Cab)).
3. Remove the rear seat back assembly. Refer to Rear Seat Back Cushion Replacement
(Extended Cab) (See: Seat Back/Service and Repair/Rear
Seat Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew
Cab) (See: Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)).
4. Remove the rear seat cushion cover and pad. Refer to Rear Seat Cushion Cover and Pad
Replacement (Crew Cab) (See: Rear Seat Cushion Cover
and Pad Replacement (Crew Cab))Rear Seat Cushion Cover and Pad Replacement (Extended
Cab) (See: Rear Seat Cushion Cover and Pad Replacement (Extended Cab)).
5. Remove the rear seat cushion frame.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10588
1. Install the rear seat cushion cover and pad to the frame. Refer to Rear Seat Cushion Cover and
Pad Replacement (Crew Cab) (See: Rear Seat
Cushion Cover and Pad Replacement (Crew Cab))Rear Seat Cushion Cover and Pad
Replacement (Extended Cab) (See: Rear Seat Cushion Cover and Pad Replacement (Extended
Cab)).
2. Install the rear seat back assembly. Refer to Rear Seat Back Cushion Replacement (Extended
Cab) (See: Seat Back/Service and Repair/Rear Seat
Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab)
(See: Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)).
3. Install the rear cupholder. Refer to Rear Seat Cup Holder Replacement (Crew Cab) (See:
Service and Repair/Rear Seat Cup Holder Replacement
(Crew Cab)).
4. Install the rear bench seat cushion in the vehicle. Refer to Rear Bench Seat Replacement (See:
Service and Repair/Rear Bench Seat Replacement
).
Rear Seat Cushion Frame Replacement (Extended Cab)
Rear Seat Cushion Frame Replacement (Extended Cab)
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10589
1. Remove the rear folding seat cushion from the vehicle. Refer to Folding Seat Replacement
(Extended Cab) (See: Service and Repair/Folding Seat
Replacement (Extended Cab)).
2. Release the J-strips (2) on the cover (1). 3. Remove the seat cushion cover from the seat
frame/pad.
Installation Procedure
1. Install the seat cushion cover over the seat frame/pad. 2. Install the J-strips (2) on the cover (1).
3. Install the rear folding seat cushion in the vehicle. Refer to Folding Seat Replacement (Extended
Cab) (See: Service and Repair/Folding Seat
Replacement (Extended Cab)).
Seat Cushion Outer Trim Panel Replacement
Seat Cushion Outer Trim Panel Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10590
Removal Procedure
1. Remove the seat back recliner handle. Refer to Driver or Passenger Seat Recliner Handle
Replacement (See: Service and Repair/Driver or
Passenger Seat Recliner Handle Replacement).
2. Remove the 3 screws retaining the trim panel to the seat. 3. Remove the front seat cushion outer
trim panel from the vehicle.
Installation Procedure
1. Align the front seat cushion outer trim panel to the seat assembly.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the 3 seat cushion outer trim panel mounting screws.
Tighten the front seat cushion outer trim panel screws to 1.5 Nm (13 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 10591
3. Install the seat back recliner handle. Refer to Driver or Passenger Seat Recliner Handle
Replacement (See: Service and Repair/Driver or
Passenger Seat Recliner Handle Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions
Seat Heater: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Seat Heater: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10704
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10705
5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10706
3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10708
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10710
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10711
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10713
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10716
6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10717
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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Information and Instructions > Page 10718
2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10720
6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10721
2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10722
4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10723
6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10724
8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10725
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10726
2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10727
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10728
4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10729
6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10731
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Information and Instructions > Page 10732
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10733
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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Information and Instructions > Page 10734
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10735
1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10736
3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10737
5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Information and Instructions > Page 10738
7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10739
9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10740
11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10742
15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10743
17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10744
19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10745
21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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Information and Instructions > Page 10746
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10747
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Information and Instructions > Page 10748
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
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Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
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Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
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* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 10764
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 10765
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 10766
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 10767
Seat Heater: Connector Views
Component Connector End Views
Heated Seat Element - Driver Back (KA1)
Heated Seat Element - Passenger Back (KA1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 10768
Seat Heater: Electrical Diagrams
Heated/Cooled Seat Schematics
Driver Seat
Passenger Seat
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 10769
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page
10770
Seat Heater: Description and Operation
Heated Seats Description and Operation
Heated Seats System Operation
The driver and front passenger seats are heated using electric heater elements located in the seat
cushions and seat backs. The heated seat control module is connected to the seat cushion
element and harness assembly, and controls the battery positive voltage used to supply the seat
heater elements. The heated seat switch and a thermistor, located in the seat cushion, are inputs
to the heated seat control module. Ignition voltage is supplied to the heated seat switch from the
HVAC 20A fuse in the underhood BEC. When the heated seat switch is in the high or low positions,
voltage is supplied through one of the internal resistors to the switch signal circuit. Once the seat
cushion has reached the desired temperature the heated seat control module will maintain the
thermistor signal circuit voltage level by switching the heater element supply circuit on or off as
necessary. The passenger heated seat switch must be enabled through the seat belt switch in
order for heated seat operation to occur.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection
> Initial Inspection and Diagnostic Overview
Seat Heater: Initial Inspection and Diagnostic Overview
Diagnostic Starting Point - Seats
Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the
Description and Operation information will help you determine the correct symptom diagnostic
procedure when a malfunction exists. Reviewing the Description and Operation information will
also help you determine if the condition described by the customer is normal operation. Refer to
Symptoms - Seat Heating and Cooling (See: Symptom Related Diagnostic Procedures/Symptoms Seat Heating and Cooling) in order to identify the correct procedure for diagnosing the system and
where the procedure is located.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection
> Initial Inspection and Diagnostic Overview > Page 10773
Seat Heater: Symptom Related Diagnostic Procedures
Symptoms - Seat Heating and Cooling
Symptoms - Seat Heating and Cooling
Important: Review the system description in order to familiarize yourself with the system functions.
Refer to Heated Seats Description and Operation (See: Description and Operation).
Visual/Physical Inspection
* Inspect for aftermarket devices which could affect the operation of the heated seat system. Refer
to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General
Diagnostics).
* Inspect the easily accessible or visible system components for obvious damage or conditions
which could cause the symptom.
Intermittent
Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing
for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests
and General Diagnostics).
Symptom List
Refer to Heated Seat Inoperative (See: Heated Seat Inoperative) in order to diagnose the
symptom.
Heated Seat Inoperative
Heated Seat Inoperative
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Circuit/System Description
Battery voltage is supplied at all times to the heated seat module from the HTD/SEATS 20A fuse
located in the underhood fuse block. Ignition voltage is supplied to the heated seat switch from the
PWR HTR SWITCH 20A fuse also located in the underhood fuse block. When the heated seat
switch is in either the HI or LO heat position, battery voltage is applied through the switch contacts,
one of the internal resistors, and the switch signal circuit to the heated seat module. In response to
this signal, the heated seat module applies battery voltage through the heater element control
circuit to the seat cushion and seat back heater elements for heated seat operation.
Reference Information Schematic Reference
Heated/Cooled Seat Schematics (See: Diagrams/Electrical Diagrams) Connector End View
Reference
Component Connector End Views (See: Diagrams/Connector Views) Description and Operation
Heated Seats Description and Operation (See: Description and Operation) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Circuit/System Verification
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection
> Initial Inspection and Diagnostic Overview > Page 10774
Driver Heated Seat
1. Ignition ON, operate the heated seat switch to the high and low heat positions. The heated seat
switch indicator should illuminate when the switch
is in the high and low positions.
‹› If the heated seat switch indicator does not illuminate or is always illuminated, refer to the Driver
Heated Seat Switch Circuit Test.
2. If the heated seat switch indicator operates normal, refer to the Heated Seat Circuit Test.
Passenger Heated Seat
1. Ignition ON, seat belt buckled, operate the heated seat switch to the high and low heat positions.
The heated seat switch indicator should illuminate
when the switch is in the high and low positions.
‹› If the heated seat switch indicator does not illuminate or is always illuminated, refer to the
Passenger Heated Seat Switch Circuit Test.
2. If the heated seat switch indicator operates normal, refer to the Heated Seat Circuit Test.
Circuit/System Testing
Driver Heated Seat Switch Circuit Test
1. Ignition OFF, disconnect the harness connector at the heated seat switch. 2. Test for less than 5
ohms between the ground circuit terminal E and ground.
‹› If greater than the specified range, test the ground circuit for an open/high resistance.
3. Ignition ON, verify that a test lamp illuminates between the ignition circuit terminal C and ground.
‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high
resistance.
4. If all circuits test normal, test or replace the heated seat switch.
Passenger Heated Seat Switch Circuit Test
1. Ignition OFF, disconnect the harness connector at the heated seat switch. 2. Test for less than 5
ohms between the ground circuit terminal E and ground.
‹› If greater than the specified range, test the ground circuit for an open/high resistance.
3. Ignition ON, verify that a test lamp illuminates between the ignition circuit terminal C and ground.
‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high
resistance.
4. Connect a test lamp between the ignition circuit terminal C and the signal circuit terminal D. 5.
Buckle and unbuckle the passenger seat belt. The test lamp should be OFF when buckled and ON
when unbuckled.
‹› If the test lamp is always on, test the signal circuit for a short to ground. If the circuit tests normal,
replace the seat belt buckle.
‹› If the test lamp is always OFF, test the signal circuit for an open/high resistance. If the circuit
tests normal, replace the seat belt buckle.
6. If all circuits test normal, test or replace the heated seat switch.
Heated Seat Circuit Test
1. Ignition OFF, disconnect the harness connector at the heated seat module. 2. Test for less than
5 ohms between the ground circuit terminal 4 and ground.
‹› If greater than the specified range, test the ground circuit for an open/high resistance.
3. Ignition ON, verify that a test lamp illuminates between the B+ circuit terminal 5 and ground.
‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance.
4. Ignition OFF, test for 2.5K ohms between the signal circuit terminal 6 and ground with the heated
seat switch in the HIGH heat position.
‹› If less than the specified value, test the signal circuit for a short to ground. If the signal circuit
tests normal, test or replace the heated seat
switch.
‹› If greater than the specified value, test the signal circuit for an open/high resistance. If the signal
circuit tests normal, test or replace the heated
seat switch.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection
> Initial Inspection and Diagnostic Overview > Page 10775
5. Test for 4.9K ohms between the signal circuit terminal C and ground with the heated seat switch
in the LOW heat position.
‹› If not the specified value, test or replace the heated seat switch.
6. Test for 2K-15K ohms between the signal circuit terminal 2 and the ground circuit terminal 4.
‹› If not within the specified range, replace the seat cushion heater element.
7. Disconnect the harness connector at the seat back heater element. 8. Test for less than 5 ohms
between the ground circuit terminal A and ground.
‹› If greater than the specified range, test the ground circuit for an open/high resistance.
9. At the seat back heater element, test for 1-10 ohms between terminal A and terminal B.
‹› If not within the specified range, replace the seat back heater element.
10. Test for 1-10 ohms between the heated seat module connector terminal 7 and the seat back
heater element connector terminal B.
‹› If not within the specified range, replace the seat cushion heater element.
11. If all circuits test normal, replace the heated seat module.
Component Test
Heated Seat Switch
1. Ignition OFF, disconnect the harness connector at the heated seat switch. 2. Test for infinite
resistance between the terminals listed below with the switch in the open position.
* Signal terminal B and ignition terminal C
* Ignition terminal C and ground terminal A
‹› If not the specified value, replace the heated seat switch.
3. Test for 2.5K ohms between the signal terminal B and the ignition terminal C with the switch in
the HIGH heat position.
‹› If not the specified value, replace the heated seat switch.
4. Test for 4.9K ohms between the signal terminal B and the ignition terminal C with the switch in
the LOW heat position.
‹› If not the specified value, replace the heated seat switch.
Repair Instructions
Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Verification Tests and Procedures) after completing the diagnostic procedure.
* Driver or Passenger Seat Back Cushion Heater Replacement (See: Service and Repair/Driver or
Passenger Seat Back Cushion Heater Replacement)
* Driver or Passenger Seat Cushion Heater Replacement (See: Service and Repair/Driver or
Passenger Seat Cushion Heater Replacement)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair >
Driver or Passenger Seat Back Cushion Heater Replacement
Seat Heater: Service and Repair Driver or Passenger Seat Back Cushion Heater Replacement
Driver or Passenger Seat Back Cushion Heater Replacement
Removal Procedure
1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and
Repair/Front Seat Replacement - Bucket). 2. Remove the seat back cover to expose the heater
element. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement (See: Seat
Back/Service and Repair/Front Seat Back Cushion Cover and Cushion Pad Replacement).
3. Disconnect the electrical harness from the heater element.
4. Remove the heater element (1) by peeling the element off the pad (2). 5. Pull the heater element
electrical harness through the hole (3) in the pad.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair >
Driver or Passenger Seat Back Cushion Heater Replacement > Page 10778
1. Install the heater element electrical harness through the hole (3) in the pad. 2. Install the
adhesive-backed heater element (1) to the pad (2) by pressing in place. 3. Connect the electrical
harness to the heater element. 4. Install the seat back cover. Refer to Front Seat Back Cushion
Cover and Cushion Pad Replacement (See: Seat Back/Service and Repair/Front
Seat Back Cushion Cover and Cushion Pad Replacement).
5. Install the seat in the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and
Repair/Front Seat Replacement - Bucket).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair >
Driver or Passenger Seat Back Cushion Heater Replacement > Page 10779
Seat Heater: Service and Repair Driver or Passenger Seat Cushion Heater Replacement
Driver or Passenger Seat Cushion Heater Replacement
Removal Procedure
1. Remove the front seat assembly from the vehicle. Refer to Front Seat Replacement - Bucket
(See: Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat
Replacement).
2. Remove the front seat cushion cover and pad. Refer to Front Seat Cushion Cover and Pad
Replacement (See: Seat Cushion/Service and
Repair/Front Seat Cushion Cover and Pad Replacement).
3. Disconnect the electrical harness from the heater element.
4. Remove the heater element (1) by peeling the element off the pad (2). 5. Pull the heater element
electrical harness through the hole (3) in the pad.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair >
Driver or Passenger Seat Back Cushion Heater Replacement > Page 10780
1. Install the heater element electrical harness through the hole (3) in the pad. 2. Install the
adhesive-backed heater element (1) to the pad (2) by pressing in place. 3. Connect the electrical
harness to the heater element. 4. Install the front seat cushion cover and pad. Refer to Front Seat
Cushion Cover and Pad Replacement (See: Seat Cushion/Service and
Repair/Front Seat Cushion Cover and Pad Replacement).
5. Install the front seat assembly in the vehicle. Refer to Front Seat Replacement - Bucket (See:
Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Locations
Seat Heater Control Module: Locations
Passenger Compartment/Roof Component Views
Under the Driver Seat Components
1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1)
5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver
Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver
Under the Passenger Seat Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Locations > Page 10784
1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor
(SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger
(KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1)
7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Locations > Page 10785
Seat Heater Control Module: Service and Repair
Front Seat Heater Control Module Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair
Seat Latch: Service and Repair
Rear Seat Back Latch Replacement
Removal Procedure
1. Remove the rear bench seat cushion from the vehicle. Refer to Rear Bench Seat Replacement
(See: Service and Repair/Rear Bench Seat
Replacement).
2. Remove the seat back cover and pad. Refer to Rear Seat Back Cushion Cover and Pad
Replacement (Crew Cab) (See: Seat Back/Service and
Repair/Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab)).
3. Remove the 2 screws (2) securing the latch release strap bracket (1) to the seat back frame.
4. Remove the 4 screws (2) securing the latch assembly (1) to the seat back frame. 5. Remove the
seat back latch from the seat back frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair >
Page 10789
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
1. Remove the seat back latch (1) to the seat back frame with the 4 screws (2).
Tighten the rear bench seat back latch mounting screws to 12 Nm (9 lb ft).
2. Install the 2 screws (2) securing the latch release strap bracket (1) to the seat back frame.
Tighten the rear bench seat back latch release strap bracket screws to 1.5 Nm (13 lb in).
3. Install the screw securing the side trim covers to the seat cushion frame.
Tighten the rear bench seat side trim cover screw to 1.5 Nm (13 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair >
Page 10790
4. Install the seat back cover and pad. Refer to Rear Seat Back Cushion Cover and Pad
Replacement (Crew Cab) (See: Seat Back/Service and
Repair/Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab)).
5. Install the rear bench seat cushion in the vehicle. Refer to Rear Bench Seat Replacement (See:
Service and Repair/Rear Bench Seat Replacement
).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service
Bulletins > Customer Interest for Seat Track: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust,
Stuck
Seat Track: Customer Interest Interior - Front Manual Seat(s) Won't Adjust, Stuck
TECHNICAL
Bulletin No.: 10-08-50-006
Date: June 02, 2010
Subject: Front Manual Seat(s) Won't Adjust Forward or Rearward, Sticks or Binds (Install Revised
Seat Adjuster Bar, Replace Seat Adjuster)
Models:
2004-2010 Chevrolet Colorado 2004-2010 GMC Canyon with Seat RPO AM6 or AR9
Condition
Some customers may comment that the front seat(s) appear to be stuck in position and they are
unable to move the seat forward or rearward in the vehicle.
Cause
This condition may be caused by the seat adjuster bar (handle) bending or coming out of position.
This may also cause damage to the plastic adjuster blocks located in the seat adjuster assembly.
Seat tracks (adjuster assemblies) that are not parallel to each other may contribute to the
development of this condition.
Correction
Use the following procedure to repair the affected seat(s).
1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket or Split Bench
Seat Replacement in SI.
2. Locate the adjuster bar (handle). Determine if the handle pin(s) have come out of the plastic
adjuster block(s).
3. If the pin is in the block, inspect the gap between the adjuster bar and the plastic adjuster blocks.
There should be no space between the two
components.
4. If the pin(s) are out of the block(s) or there is a gap, the adjuster bar needs to be replaced with
the revised part listed below.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service
Bulletins > Customer Interest for Seat Track: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust,
Stuck > Page 10799
5. Locate and remove the two fasteners that retain the adjuster bar to the inner and outer seat
adjuster assemblies. 6. Remove the adjuster bar. Note that the bar is curved upward at the front.
7. With the adjuster bar removed, inspect the inboard and outboard plastic adjuster blocks for any
damage where the adjuster bar engages into the
holes in the adjuster blocks. If any damage is detected, the affected seat adjuster assembly must
be replaced. The seat adjuster assemblies are available individually (inboard and outboard). Only
replace the component that is damaged. Refer to Manual Seat Adjuster Mechanism Replacement
in SI for replacement procedures.
8. Install the revised adjuster bar. When installing the bar, do not apply pressure to the outer ends
of the bar, it may bend at the pivot mount holes.
Ensure that the curved portion of the bar is in the upward position.
9. With the bar installed, inspect the area where the adjuster bar engages the inboard and outboard
adjuster blocks. Ensure that there is no gap
between the two components.
10. Reinstall the seat. Refer to Front Seat Replacement - Bucket or Split Bench Seat Replacement
in SI.
11. Before tightening the seat mounting bolts, ensure that the inboard and outboard seat tracks are
parallel and spaced 305 mm (12 in) apart as shown. 12. With the seat installed, verify the seat
adjuster function.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service
Bulletins > Customer Interest for Seat Track: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust,
Stuck > Page 10800
Warranty Information
For vehicles repaired under warranty, use:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Track: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't
Adjust, Stuck
Seat Track: All Technical Service Bulletins Interior - Front Manual Seat(s) Won't Adjust, Stuck
TECHNICAL
Bulletin No.: 10-08-50-006
Date: June 02, 2010
Subject: Front Manual Seat(s) Won't Adjust Forward or Rearward, Sticks or Binds (Install Revised
Seat Adjuster Bar, Replace Seat Adjuster)
Models:
2004-2010 Chevrolet Colorado 2004-2010 GMC Canyon with Seat RPO AM6 or AR9
Condition
Some customers may comment that the front seat(s) appear to be stuck in position and they are
unable to move the seat forward or rearward in the vehicle.
Cause
This condition may be caused by the seat adjuster bar (handle) bending or coming out of position.
This may also cause damage to the plastic adjuster blocks located in the seat adjuster assembly.
Seat tracks (adjuster assemblies) that are not parallel to each other may contribute to the
development of this condition.
Correction
Use the following procedure to repair the affected seat(s).
1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket or Split Bench
Seat Replacement in SI.
2. Locate the adjuster bar (handle). Determine if the handle pin(s) have come out of the plastic
adjuster block(s).
3. If the pin is in the block, inspect the gap between the adjuster bar and the plastic adjuster blocks.
There should be no space between the two
components.
4. If the pin(s) are out of the block(s) or there is a gap, the adjuster bar needs to be replaced with
the revised part listed below.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Track: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't
Adjust, Stuck > Page 10806
5. Locate and remove the two fasteners that retain the adjuster bar to the inner and outer seat
adjuster assemblies. 6. Remove the adjuster bar. Note that the bar is curved upward at the front.
7. With the adjuster bar removed, inspect the inboard and outboard plastic adjuster blocks for any
damage where the adjuster bar engages into the
holes in the adjuster blocks. If any damage is detected, the affected seat adjuster assembly must
be replaced. The seat adjuster assemblies are available individually (inboard and outboard). Only
replace the component that is damaged. Refer to Manual Seat Adjuster Mechanism Replacement
in SI for replacement procedures.
8. Install the revised adjuster bar. When installing the bar, do not apply pressure to the outer ends
of the bar, it may bend at the pivot mount holes.
Ensure that the curved portion of the bar is in the upward position.
9. With the bar installed, inspect the area where the adjuster bar engages the inboard and outboard
adjuster blocks. Ensure that there is no gap
between the two components.
10. Reinstall the seat. Refer to Front Seat Replacement - Bucket or Split Bench Seat Replacement
in SI.
11. Before tightening the seat mounting bolts, ensure that the inboard and outboard seat tracks are
parallel and spaced 305 mm (12 in) apart as shown. 12. With the seat installed, verify the seat
adjuster function.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Track: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't
Adjust, Stuck > Page 10807
Warranty Information
For vehicles repaired under warranty, use:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Door Component Views
Power Door Lock Switch: Locations Door Component Views
Door Component Views
Driver Door Components
1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker
- Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch
(DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF)
Front Passenger Door Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Door Component Views > Page 10813
1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door
Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Door Component Views > Page 10814
Power Door Lock Switch: Locations Harness Routing Views
Harness Routing Views
Driver Door Harness Routing
1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside
Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body
Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver
Front Passenger Door Harness Routing
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Door Component Views > Page 10815
1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front
Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body
Harness) 9 - X210 (Body Harness to Front Passenger Door Harness)
Right Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Door Component Views > Page 10816
1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock
Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door
Harness)
Left Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Door Component Views > Page 10817
1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness
to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 10818
Power Door Lock Switch: Diagrams
Component Connector End Views
Door Lock/Window Switch - Driver X1 (A31/AU3)
Door Lock/Window Switch - Driver X2 (A31/AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 10819
Door Lock/Window Switch - Passenger (A31/AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 10820
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door
Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Driver Door
Door Lock Switch Replacement - Driver Door
Removal Procedure
1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the front
of the switch plate up to disengage clip. 3. Remove the switch plate out of the door trim panel
opening.
4. Disconnect the electrical connectors (3, 4) from the switches (2, 5). 5. Remove the switch plate
assembly (1) from the vehicle. 6. If replacing only the switches, remove the switches from the plate.
7. If replacing only the switch plate, retain the switches for transfer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door > Page 10823
Installation Procedure
1. Install the switches (2, 5) to the switch plate (1). 2. Connect the electrical connectors (3, 4) to the
switches (2, 5).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the switch plate assembly to the door trim panel with the 2 screws.
Tighten the front door switch plate screws to 2 Nm (18 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door > Page 10824
Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Passenger Front
Door Lock Switch Replacement - Passenger Front
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Door Component Views
Power Mirror Switch: Locations Door Component Views
Door Component Views
Driver Door Components
1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker
- Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch
(DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Door Component Views > Page 10829
Power Mirror Switch: Locations Harness Routing Views
Harness Routing Views
Driver Door Harness Routing
1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside
Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body
Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 10830
Power Mirror Switch: Diagrams
Component Connector End Views
Outside Rearview Mirror Switch (DE6)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations
Power Seat Switch: Locations
Passenger Compartment/Roof Component Views
Under the Driver Seat Components
1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1)
5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver
Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver
Passenger Seat Components - 2 of 2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 10834
1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence
System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 10835
Power Seat Switch: Diagrams
Component Connector End Views
Seat Adjuster Switch - Driver X1 (AG1)
Seat Adjuster Switch - Driver X2 (AG1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 10836
Seat Adjuster Switch - Passenger (AG2)
Seat Lumbar Adjuster Switch - Driver (AG1)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 10837
Seat Lumbar Adjuster Switch - Passenger (AG2)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Power Seat Switch Replacement
Power Seat Switch: Service and Repair Power Seat Switch Replacement
Power Seat Switch Replacement
Removal Procedure
1. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel
Replacement (See: Seats/Seat Cushion/Service and
Repair/Seat Cushion Outer Trim Panel Replacement).
2. Remove the switch bezel from the seat assembly. Refer to Driver or Passenger Seat Adjuster
Switch Bezel Replacement (See: Seats/Service and
Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
3. Remove the buttons from the switch (2).
4. Release the tabs (1) that retain the seat switch (2) to the seat bezel.
5. Disconnect the power seat switch harness (1) from the seat harness.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Power Seat Switch Replacement > Page 10840
6. Remove the power seat switch from the seat bezel.
Installation Procedure
1. Connect the power seat switch harness (1) to the seat harness.
2. Install the power seat switch (2) to the seat bezel. Verify that the retaining tabs (1) are fully
seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat
assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See:
Seats/Service
and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
5. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement
(See: Seats/Seat Cushion/Service and Repair/Seat
Cushion Outer Trim Panel Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Power Seat Switch Replacement > Page 10841
Power Seat Switch: Service and Repair Lumbar Switch Replacement
Lumbar Switch Replacement
Removal Procedure
1. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel
Replacement (See: Seats/Seat Cushion/Service and
Repair/Seat Cushion Outer Trim Panel Replacement).
2. Remove the switch bezel from the seat assembly. Refer to Driver or Passenger Seat Adjuster
Switch Bezel Replacement (See: Seats/Service and
Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
3. Remove the buttons from the switch (3).
4. Release the tabs (4) that retain the seat switch (3) to the seat bezel.
5. Disconnect the lumbar switch harness (1) from the seat harness.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Power Seat Switch Replacement > Page 10842
6. Remove the lumbar switch from the seat bezel.
Installation Procedure
1. Connect the lumbar switch harness (1) to the seat harness.
2. Install the lumbar switch (3) to the seat bezel. Verify that the retaining tabs (4) are fully seated. 3.
Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Refer to
Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Seats/Service
and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement).
5. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement
(See: Seats/Seat Cushion/Service and Repair/Seat
Cushion Outer Trim Panel Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations
Sunroof / Moonroof Switch: Locations
Passenger Compartment/Roof Component Views
Front of the Headliner Components (CF5)
1 - Sunroof Switch X2 2 - Sunroof Opening 3 - G300 4 - Sunroof Motor 5 - Sunroof Switch 6 Sunroof Switch X1 7 - Sunroof Ground Lead
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 10846
Sunroof / Moonroof Switch: Diagrams
Component Connector End Views
Sunroof Switch (CF5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 10847
Sunroof / Moonroof Switch: Service and Repair
Sunroof Switch Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and
Repair > Endgate Lower Hinge Replacement - Body Side
Tailgate Hinge: Service and Repair Endgate Lower Hinge Replacement - Body Side
Endgate Lower Hinge Replacement - Body Side
Removal Procedure
1. Remove the endgate from the vehicle. Refer to Endgate Replacement (See: Service and
Repair). 2. Remove the bolts retaining the endgate hinge to the body. 3. Remove the endgate
hinge from the body.
Installation Procedure
1. Install the endgate hinge to the body.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and
Repair > Endgate Lower Hinge Replacement - Body Side > Page 10853
2. Install the bolts retaining the endgate hinge to the body and tighten to 20 Nm (15 lb ft). 3. Install
the endgate to the vehicle. Refer to Endgate Replacement (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and
Repair > Endgate Lower Hinge Replacement - Body Side > Page 10854
Tailgate Hinge: Service and Repair Endgate Lower Hinge Replacement - Endgate Side
Endgate Lower Hinge Replacement - Endgate Side
Removal Procedure
1. Remove the endgate from the vehicle. Refer to Endgate Replacement (See: Service and
Repair). 2. Remove the bolts retaining the endgate hinge to the endgate. 3. Remove the endgate
hinge from the endgate.
Installation Procedure
1. Install the endgate hinge to the endgate.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and
Repair > Endgate Lower Hinge Replacement - Body Side > Page 10855
2. Install the bolts retaining the endgate hinge to the endgate and tighten to 20 Nm (15 lb ft). 3.
Install the endgate to the vehicle. Refer to Endgate Replacement (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and
Repair > Endgate Latch and Cable Assembly Replacement
Tailgate Latch: Service and Repair Endgate Latch and Cable Assembly Replacement
Endgate Latch and Cable Assembly Replacement
Removal Procedure
1. Open and support the endgate. 2. Remove the endgate cover. Refer to Pickup Box Endgate
Latch Cover Replacement (). 3. Disconnect the clips (1) retaining the latch rods (2) to the handle. 4.
Remove the latch rods (2) from the retaining clips (1).
5. Remove the support cable (1) from the endgate striker bolt by sliding the cable forward and off
the striker bolt head.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and
Repair > Endgate Latch and Cable Assembly Replacement > Page 10860
6. Remove the bolts retaining the latch/support cable assembly to the endgate. 7. Remove the
latch assembly from the endgate.
Installation Procedure
1. Install the latch/support cable assembly to the endgate, ensuring the latch rod is oriented correct
to the endgate handle.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the latch assembly to the endgate.
Tighten the latch/support cable assembly bolts to 25 Nm (18 lb ft).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and
Repair > Endgate Latch and Cable Assembly Replacement > Page 10861
3. Install the support cable (1) onto the bolt head of the endgate striker bolt.
4. Install the latch rods (2) into the retaining clips (1). 5. Connect the clips (1) retaining the latch
rods (2) to the endgate handle. 6. Install the endgate cover. Refer to Pickup Box Endgate Latch
Cover Replacement (). 7. Close the endgate.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and
Repair > Endgate Latch and Cable Assembly Replacement > Page 10862
Tailgate Latch: Service and Repair Pickup Box Endgate Striker Replacement
Pickup Box Endgate Striker Replacement
Removal Procedure
1. Open and support the endgate. 2. Remove the support cable (1) from the endgate striker bolt by
sliding the cable forward and off the striker bolt head. 3. Remove the bolts retaining the endgate
striker to the body. 4. Remove the endgate striker from the body.
Installation Procedure
1. Install the endgate striker to the body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and
Repair > Endgate Latch and Cable Assembly Replacement > Page 10863
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the endgate striker to the body.
Tighten the endgate striker bolts to 25 Nm (18 lb ft).
3. Install the support cable (1) onto the head of the striker bolt, sliding the cable rearward until the
bolt head is retaining in the keyhole slot. 4. Remove the endgate support and close the endgate.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service
and Repair
Tailgate Release Handle: Service and Repair
Endgate Handle Replacement
Removal Procedure
1. Remove the endgate cover. Refer to Pickup Box Endgate Latch Cover Replacement (). 2.
Disconnect the clips (1) retaining the endgate latch rods (2) to the endgate handle. 3. Remove the
endgate latch rods (2) from the retaining clips (1).
4. Remove the bolts retaining the endgate handle to the endgate. 5. Remove the endgate handle
from the endgate. 6. Remove the lock cylinder from the endgate handle if equipped. Refer to
Endgate Lock Cylinder Replacement (See: Locks/Door Locks/Door
Lock Cylinder/Service and Repair).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service
and Repair > Page 10867
1. Install the lock cylinder to the endgate handle if equipped. Refer to Endgate Lock Cylinder
Replacement (See: Locks/Door Locks/Door Lock
Cylinder/Service and Repair).
2. Install the endgate handle to the endgate.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the bolts retaining the endgate handle to the endgate.
Tighten the endgate handle bolts to 9 Nm (80 lb in).
4. Install the endgate latch rods (2) to the retaining clips (1) on the endgate handle. 5. Connect the
clips (1) retaining the endgate latch rods (2) to the handle. 6. Install the endgate cover. Refer to
Pickup Box Endgate Latch Cover Replacement ().
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Tie Down Hook / Bracket > Component Information > Service and
Repair
Tie Down Hook / Bracket: Service and Repair
Pickup Box Tie Down Loop Replacement
Removal Procedure
Warning: Refer to Approved Equipment for Collision Repair Warning (See: Service
Precautions/Approved Equipment for Collision Repair Warning).
1. Locate and drill out the spot welds. 2. Remove the tie down loop.
Installation Procedure
1. Prepare all mating surfaces as necessary. 2. Apply GM-approved Weld-Thru coating or
equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair ().
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Tie Down Hook / Bracket > Component Information > Service and
Repair > Page 10871
3. Position the tie down loop. 4. Plug weld accordingly. 5. Clean and prepare all welded surfaces.
6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to
Anti-Corrosion Treatment and Repair (). 7. Paint and repair the area. Refer to Basecoat/Clearcoat
Paint Systems (See: Paint, Striping and Decals/Paint/Application and
ID/Basecoat/Clearcoat Paint Systems).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair
Towing Hook / Bracket: Service and Repair
Tow Hook Replacement
Removal Procedure
1. Remove the front bumper. Refer to Front Bumper Replacement (See: Bumper/Front
Bumper/Service and Repair).
2. Remove the right tow hook nuts and bolts from the frame rail. 3. Remove the right tow hook from
the vehicle.
4. Remove the left tow hook nuts and bolts from the frame rail. 5. Remove the left tow hook from
the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair
> Page 10875
1. Install the left tow hook to the frame rail.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the nuts and the bolts to the frame rail and tighten the bolts to 100 Nm (74 lb ft).
3. Install the left tow hook to the frame rail. 4. Install the nuts and the bolts to the frame rail and
tighten the bolts to 100 Nm (74 lb ft). 5. Install the front bumper. Refer to Front Bumper
Replacement (See: Bumper/Front Bumper/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Component Information > Service and
Repair
Truck Bed Cover: Service and Repair
Pickup Box Liner Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service
and Repair
Cowl Moulding / Trim: Service and Repair
Air Inlet Grille Panel Replacement
Removal Procedure
1. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper
and Washer Systems/Wiper Arm/Service and
Repair).
2. Remove the air inlet grill panel push-pin retainers. 3. Disconnect the washer hose. 4. Remove
the air inlet grille panel from the vehicle.
Installation Procedure
1. Position the air inlet grille panel to the vehicle. 2. Connect the washer hose.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service
and Repair > Page 10885
3. Install the push-pin retainers. 4. Install the windshield wiper arms. Refer to Windshield Wiper
Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Service and Repair > Auxiliary Weatherstrip Replacement
Front Door Weatherstrip: Service and Repair Auxiliary Weatherstrip Replacement
Auxiliary Weatherstrip Replacement
Crew cab shown, others similar.
Removal Procedure
1. Open the front and rear door, as necessary. 2. Remove the auxiliary weatherstrip by pulling the
weatherstrip (1) from the roof pinchweld flange (2).
Installation Procedure
1. Install the auxiliary weatherstrip to the roof pinchweld flange by pressing the weatherstrip (1)
onto the roof flange (2), until it is fully seated. 2. Close the front and rear door, as necessary.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Service and Repair > Auxiliary Weatherstrip Replacement > Page 10891
Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement
(Extended)
Front Door Opening Weatherstrip Replacement (Extended)
Removal Procedure
1. Open the front and rear door. 2. Remove the front door opening weatherstrip (1) from the
opening pinchweld flange. 3. Remove the front door opening weatherstrip from the vehicle.
Installation Procedure
1. Align the paint dot on the front door weatherstrip to the notch (2) in the upper rear corner of the
pitchweld flange. 2. Starting at the notch (2) in the upper rear corner, press the front door opening
weatherstrip (1) onto the pinchweld flange until it is fully seated. 3. Pull the cord (3) on the front
door opening weatherstrip, ensuring the weatherstrip lip overlaps the interior trim panels and
headliner.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Service and Repair > Auxiliary Weatherstrip Replacement > Page 10892
4. Close the front door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Service and Repair > Auxiliary Weatherstrip Replacement > Page 10893
Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement
(Regular, Crew)
Front Door Opening Weatherstrip Replacement (Regular, Crew)
Removal Procedure
1. Open the front door. 2. Remove the lower center pillar panel. Refer to Center Pillar Lower Trim
Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service
and Repair).
3. Remove the front door opening weatherstrip (2) from the door opening pinchweld flange (1). 4.
Remove the front door opening weatherstrip from the vehicle.
Installation Procedure
1. Position the front door opening weatherstrip to the pinchweld flange.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Service and Repair > Auxiliary Weatherstrip Replacement > Page 10894
2. Starting at the upper rear corner, press the front door opening weatherstrip (2) onto the
pinchweld flange (1) until it is fully seated. 3. Install the lower center pillar panel. Refer to Center
Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and
Repair).
4. Pull the cord (3) on the front door opening weatherstrip ensuring the weatherstrip lip overlaps the
interior trim panels and headliner. 5. Close the front door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Service and Repair > Auxiliary Weatherstrip Replacement > Page 10895
Front Door Weatherstrip: Service and Repair Front Side Door Weatherstrip Replacement
(Extended)
Front Side Door Weatherstrip Replacement (Extended)
Tools Required
J 38778 Door Trim Pad Clip Remover or Equivalent
Removal Procedure
1. Open the front door. 2. Remove the upper weatherstrip mold from the door by removing the
integral weatherstrip pushpin (2) from the door using J 38778 , or
equivalent.
3. Remove the lower weatherstrip mold from the door removing the integral weatherstrip pushpin
(3) from the door using J 38778 , or equivalent. 4. Remove the weatherstrip from around the door
by inserting J 38778 , or equivalent, under the weatherstrip (1), and releasing the integral retainers
from the door frame.
5. Remove the weatherstrip from the door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Service and Repair > Auxiliary Weatherstrip Replacement > Page 10896
1. Position the weatherstrip to the front door. 2. Install the upper weatherstrip mold to the door
using the integral weatherstrip pushpin (2). 3. Install the lower weatherstrip mold to the door using
the integral weatherstrip pushpin (3). 4. Install the weatherstrip around the front door frame using
the integral retainers. 5. Close the front door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Service and Repair > Auxiliary Weatherstrip Replacement > Page 10897
Front Door Weatherstrip: Service and Repair Front Side Door Weatherstrip Replacement (Regular,
Crew)
Front Side Door Weatherstrip Replacement (Regular, Crew)
Tools Required
J 38778 Door Trim Pad Clip Remover or Equivalent
Removal Procedure
1. Open the front door. 2. Remove the weatherstrip from around the door by inserting J 38778 , or
equivalent , under the weatherstrip (1) and releasing the integral retainers
from the door frame.
3. Remove the weatherstrip from the front door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Service and Repair > Auxiliary Weatherstrip Replacement > Page 10898
1. Position the weatherstrip to the front door. 2. Install the weatherstrip around the front door frame
using the integral retainers. 3. Close the front door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service
and Repair > Hood Front Seal Replacement
Hood Weatherstrip: Service and Repair Hood Front Seal Replacement
Hood Front Seal Replacement
Removal Procedure
1. Open the hood.
2. Remove the front hood seal by pulling downward on the seal, starting from one end.
Installation Procedure
1. Open the hood.
2. Install the front hood seal by pressing the retainers into the hood openings.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service
and Repair > Hood Front Seal Replacement > Page 10903
3. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service
and Repair > Hood Front Seal Replacement > Page 10904
Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement
Hood Rear Seal Replacement
Removal Procedure
1. Open the hood. 2. Grasp the rear hood seal at each retainer and lift upwards to remove. 3.
Remove the seal from the upper cowl panel.
Installation Procedure
1. Position the seal to the upper cowl panel. 2. Insert each retainer into the holes in the body. 3.
Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement
Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement
Rear Door Opening Weatherstrip Replacement
Removal Procedure
1. Open the rear door. 2. Remove the lower center pillar trim panel. Refer to Center Pillar Lower
Trim Panel Replacement (See: Interior Moulding / Trim/Trim
Panel/Service and Repair).
3. Remove the rear door opening weatherstrip (2) from the door opening pinchweld flange (1). 4.
Remove the rear door opening weatherstrip from the vehicle.
Installation Procedure
1. Position the rear door opening weatherstrip to the pinchweld flange.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10909
2. Starting at the upper rear corner, press the rear door opening weatherstrip (2) onto the
pinchweld flange (1) until it is fully seated. 3. Install the lower center pillar trim panel. Refer to
Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim
Panel/Service and Repair).
4. Pull the cord (3) on the rear door opening weatherstrip ensuring the weatherstrip lip overlaps the
interior trim panels and headliner. 5. Close the rear door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10910
Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Replacement
Rear Door Weatherstrip Replacement
Tools Required
J 38778 Door Trim Pad Clip Remover or Equivalent
Removal Procedure
1. Open the rear door. 2. Remove the weatherstrip from around the door by inserting J 38778 , or
equivalent, under the weatherstrip and releasing the integral retainers (2)
from the door frame.
3. Remove the weatherstrip from the rear door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10911
1. Position the weatherstrip to the rear door. 2. Install the weatherstrip around the rear door frame
using the integral retainers (2). 3. Close the rear door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10912
Rear Door Weatherstrip: Service and Repair Rear Side Access Door Auxiliary Weatherstrip
Replacement
Rear Side Access Door Auxiliary Weatherstrip Replacement
Removal Procedure
1. Open the front and side access doors. 2. Remove the rear door outer auxiliary weatherstrip by
pulling the weatherstrip from the rear door pinchweld flange.
Installation Procedure
1. Install the rear door auxiliary weatherstrip to the rear door pinchweld flange, by pressing the
weatherstrip into place until it is fully seated. 2. Close the front and side doors.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10913
Rear Door Weatherstrip: Service and Repair Rear Side Door Wedge Replacement - Body Side
Rear Side Door Wedge Replacement - Body Side
Removal Procedure
1. Open the rear side access door. 2. Apply tape to the area around the wedge to protect the paint.
3. Heat the wedge (1) using a heat gun 152 mm (6 in) from the surface. 4. Apply the heat using a
circular motion for about 30 seconds. 5. Remove the wedge from the body using a plastic,
flat-bladed tool. 6. Remove all adhesive from the body using 3M Scotch Brite molding adhesive
remover disk 3M P/N 07201, or equivalent. 7. Clean the body surface using varnish makers and
painters (VMP) naptha.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10914
1. Warm the body surface with a heat gun 152 mm (6 in) from the surface to a minimum of 21°C
(70°F). 2. Remove the backing from the wedge (1). 3. Align the tabs on the wedge to the holes in
the body. 4. Press the wedge to the body surface. 5. Inspect the wedge for proper adhesion. 6.
Remove the tape from the area around the wedge. 7. Close the rear side access door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10915
Rear Door Weatherstrip: Service and Repair
Rear Door Opening Weatherstrip Replacement
Rear Door Opening Weatherstrip Replacement
Removal Procedure
1. Open the rear door. 2. Remove the lower center pillar trim panel. Refer to Center Pillar Lower
Trim Panel Replacement (See: Interior Moulding / Trim/Trim
Panel/Service and Repair).
3. Remove the rear door opening weatherstrip (2) from the door opening pinchweld flange (1). 4.
Remove the rear door opening weatherstrip from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10916
1. Position the rear door opening weatherstrip to the pinchweld flange. 2. Starting at the upper rear
corner, press the rear door opening weatherstrip (2) onto the pinchweld flange (1) until it is fully
seated. 3. Install the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel
Replacement (See: Interior Moulding / Trim/Trim
Panel/Service and Repair).
4. Pull the cord (3) on the rear door opening weatherstrip ensuring the weatherstrip lip overlaps the
interior trim panels and headliner. 5. Close the rear door.
Rear Door Weatherstrip Replacement
Rear Door Weatherstrip Replacement
Tools Required
J 38778 Door Trim Pad Clip Remover or Equivalent
Removal Procedure
1. Open the rear door. 2. Remove the weatherstrip from around the door by inserting J 38778 , or
equivalent, under the weatherstrip and releasing the integral retainers (2)
from the door frame.
3. Remove the weatherstrip from the rear door.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10917
1. Position the weatherstrip to the rear door. 2. Install the weatherstrip around the rear door frame
using the integral retainers (2). 3. Close the rear door.
Rear Side Access Door Auxiliary Weatherstrip Replacement
Rear Side Access Door Auxiliary Weatherstrip Replacement
Removal Procedure
1. Open the front and side access doors. 2. Remove the rear door outer auxiliary weatherstrip by
pulling the weatherstrip from the rear door pinchweld flange.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10918
1. Install the rear door auxiliary weatherstrip to the rear door pinchweld flange, by pressing the
weatherstrip into place until it is fully seated. 2. Close the front and side doors.
Rear Side Door Wedge Replacement - Body Side
Rear Side Door Wedge Replacement - Body Side
Removal Procedure
1. Open the rear side access door. 2. Apply tape to the area around the wedge to protect the paint.
3. Heat the wedge (1) using a heat gun 152 mm (6 in) from the surface. 4. Apply the heat using a
circular motion for about 30 seconds. 5. Remove the wedge from the body using a plastic,
flat-bladed tool. 6. Remove all adhesive from the body using 3M Scotch Brite molding adhesive
remover disk 3M P/N 07201, or equivalent. 7. Clean the body surface using varnish makers and
painters (VMP) naptha.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10919
Installation Procedure
1. Warm the body surface with a heat gun 152 mm (6 in) from the surface to a minimum of 21°C
(70°F). 2. Remove the backing from the wedge (1). 3. Align the tabs on the wedge to the holes in
the body. 4. Press the wedge to the body surface. 5. Inspect the wedge for proper adhesion. 6.
Remove the tape from the area around the wedge. 7. Close the rear side access door.
Rear Side Door Wedge Replacement - Door Side
Rear Side Door Wedge Replacement - Door Side
Removal Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10920
1. Open the rear side access door. 2. Remove the wedge from the side access door by squeezing
the retainer clip on the wedge and rotating the wedge downward.
Installation Procedure
1. Install the wedge to the side access door by inserting the tabs into the slots on the door and
rotating the wedge up until the retaining clip is fully
seated.
2. Close the rear side access door.
Weatherstrip Replacement Rear Side Access Door
Weatherstrip Replacement Rear Side Access Door
Tools Required
J 38778 Door Trim Pad Clip Remover or Equivalent
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10921
Removal Procedure
1. Open the front and rear side access doors. 2. Remove the upper molded detail from the front of
the side access door, by inserting J 38778 under the weatherstrip mold and releasing the
integral retaining pins (3) on the mold to the door.
3. Remove the lower molded detail from the front of the side access door, by inserting J 38778
under the weatherstrip mold and releasing the
integral retaining pins (1) on the mold to the door.
4. Remove the weatherstrip from around the door, by inserting J 38778 under the weatherstrip on
releasing the integral pins from the door. 5. Remove the weatherstrip from the side access door.
Installation Procedure
1. Position the weatherstrip to the rear side access door. 2. Install the upper molded detail to the
front of the rear side access door using the integral retaining pins (1). 3. Install the lower molded
detail to the front of the rear side access door using the integral retaining pins (1). 4. Install the
weatherstrip around the rear door frame using the integral retainers.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10922
5. Close the front and rear side access doors.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun
> 09 > Body - Water leaks/ Wind Noise From The Sunroof
Sunroof / Moonroof Weatherstrip: Customer Interest Body - Water leaks/ Wind Noise From The
Sunroof
TECHNICAL
Bulletin No.: 07-08-67-001B
Date: June 22, 2009
Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and
Apply Sealer)
Models:
2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof
Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate
Bulletin 07-08-67-001A (Section 08 - Body & Accessories).
Condition
Some customers may comment on water entering into the vehicle from the sunroof area. Other
customers may comment on a wind noise or whistle noise heard from the sunroof area when
driving at different speeds.
Design
The sunroof module is designed to be completely sealed at the roof panel to help prevent water
from traveling past the glass panel seal. The sunroof glass assembly does not have any glass
panel adjustments. The sunroof assembly does not contain a water management drain tube
system. When operating the sunroof, the glass panel moves rearward and slides up above the roof
panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove
excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some
water may enter inside the vehicle.
Cause
Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the
upper sunroof frame assembly.
Wind or Whistle Noise Test Procedure
Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI.
Water Hose Test Procedure
Perform a water hose test to determine where the leak is entering the sunroof assembly.
Important Use a water hose without the nozzle attached at a controlled medium volume water flow.
1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1)
like in the graphic above is not flush, make sure
no parts are broken or missing from the sunroof module assembly.
2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with
warm water to clean the seals. Use GM(TM) Glass
Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks.
3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open
position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6.
Remove the outer trim cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun
> 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10931
7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8.
Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water
test to verify the leak concern.
10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of
the following four areas:
1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be
entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the
sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip
holder.
11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire
outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking
tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one
inch of tape at a time until the source of the leak can be
pinpointed.
14. Proceed with the water test while removing the masking tape along the right front outer sunroof
frame and roof panel until the complete area has
been tested.
15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame
with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start
water testing while removing the masking tape from the left front corner of the sunroof glass; then
proceed along to the right front corner of
the glass until the complete area has been tested.
18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing
and mark the entry point of the water. 20. The leak could be from more than one area, so
determine which conditions apply and follow the recommended corrections below.
Condition 1
The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof
frame.
Cause 1
The dry foam seal on the upper sunroof frame assembly may have collapsed or has become
distorted, causing the leak.
Correction 1
Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to
the outer edge of the upper sunroof frame using the procedure listed below:
1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI.
Important Note the size, color and locations of the lower sunroof frame screws when removing
them.
2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame.
Important Do Not remove the (red) TORX(R) screws from the track.
3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower
frame from the sunroof module assembly.
Important Have a clean workbench with a flat protective cover. The cover will help protect the
sunroof glass when the glass is placed face down on the bench.
5. Remove the sunroof module and window from the vehicle and place the glass side down on a
clean bench.
Tip The sunroof window can now be manually moved forward or backward.
6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of
the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the
sunroof frame. If the
sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun
> 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10932
8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if
no adhesive has been used. If adhesive has been
used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner,
P/N 08984, or equivalent, to clean the roof panel.
9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare
edges of the roof panel opening for the sunroof
module. This grease is recommended for use on any bare edges around the sunroof opening. An
acid brush can be used to apply the grease.
10. A caulk gun applicator will be needed to apply the adhesive (1).
Tip You may want to use some disposable gloves to keep the adhesive from getting onto your
hands.
11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame
assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install
the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame
assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Manually push the sunroof window to the full open position. This will allow the window, motors
and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement
in SI. 18. Verify the proper operation of the sunroof.
19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade
while using a 3M(TM) General Purpose Cleaner,
P/N 08984, or equivalent, as shown in the graphic above.
20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover.
Refer to Sunroof Front Trim Cover Replacement in SI.
Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open
the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are
installed properly.
22. Install the outer trim cover and four screws.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun
> 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10933
Tighten Tighten the screws to 1 Nm (9 lb in).
Condition 2
A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the
window weather seal (4).
Cause 2
The seal on the upper sunroof frame assembly may not have enough sealant under the seal.
Correction 2
Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip
sealing flange located in the upper sunroof frame.
Condition 3
A leak from the sunroof window glass and sunroof window seal.
Cause 3
The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass
to seal properly.
Correction 3
Replace the sunroof window seal following the steps below:
1. Open the sunshade to the full open position.
2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal
Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun
> 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10934
Condition 4
A leak from around the sunroof glass holder clip, known as a "blow out clip" (1).
Cause 4
A lack of adhesive sealant under the sunroof window holder clip.
Correction 4
Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the
upper frame clip using the steps below.
1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove
the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two
screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the
two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to
the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws.
Tighten Tighten the two screws to 1 Nm (9 lb in).
Important The chamfered edge of the gear goes toward the motor when reinstalling the gear.
10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws.
Tighten Tighten the screw to 2 Nm (18 lb in).
13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install
the sunroof motor assembly. 15. Install the sunroof motor screws and tighten.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim
cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and
four screws.
Tighten Tighten the screws to 1 Nm (9 lb in).
Waterleak Odor in Vehicle
Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles.
Dry out any wet components. Refer to Floor Carpet Drying in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun
> 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10935
Parts Information
To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144
from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to
place orders. The dealer also has the option to complete a referral request form to purchase the
product through a local supplier.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof
Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Water leaks/ Wind Noise
From The Sunroof
TECHNICAL
Bulletin No.: 07-08-67-001B
Date: June 22, 2009
Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and
Apply Sealer)
Models:
2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof
Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate
Bulletin 07-08-67-001A (Section 08 - Body & Accessories).
Condition
Some customers may comment on water entering into the vehicle from the sunroof area. Other
customers may comment on a wind noise or whistle noise heard from the sunroof area when
driving at different speeds.
Design
The sunroof module is designed to be completely sealed at the roof panel to help prevent water
from traveling past the glass panel seal. The sunroof glass assembly does not have any glass
panel adjustments. The sunroof assembly does not contain a water management drain tube
system. When operating the sunroof, the glass panel moves rearward and slides up above the roof
panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove
excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some
water may enter inside the vehicle.
Cause
Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the
upper sunroof frame assembly.
Wind or Whistle Noise Test Procedure
Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI.
Water Hose Test Procedure
Perform a water hose test to determine where the leak is entering the sunroof assembly.
Important Use a water hose without the nozzle attached at a controlled medium volume water flow.
1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1)
like in the graphic above is not flush, make sure
no parts are broken or missing from the sunroof module assembly.
2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with
warm water to clean the seals. Use GM(TM) Glass
Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks.
3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open
position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6.
Remove the outer trim cover.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10941
7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8.
Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water
test to verify the leak concern.
10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of
the following four areas:
1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be
entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the
sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip
holder.
11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire
outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking
tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one
inch of tape at a time until the source of the leak can be
pinpointed.
14. Proceed with the water test while removing the masking tape along the right front outer sunroof
frame and roof panel until the complete area has
been tested.
15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame
with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start
water testing while removing the masking tape from the left front corner of the sunroof glass; then
proceed along to the right front corner of
the glass until the complete area has been tested.
18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing
and mark the entry point of the water. 20. The leak could be from more than one area, so
determine which conditions apply and follow the recommended corrections below.
Condition 1
The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof
frame.
Cause 1
The dry foam seal on the upper sunroof frame assembly may have collapsed or has become
distorted, causing the leak.
Correction 1
Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to
the outer edge of the upper sunroof frame using the procedure listed below:
1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI.
Important Note the size, color and locations of the lower sunroof frame screws when removing
them.
2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame.
Important Do Not remove the (red) TORX(R) screws from the track.
3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower
frame from the sunroof module assembly.
Important Have a clean workbench with a flat protective cover. The cover will help protect the
sunroof glass when the glass is placed face down on the bench.
5. Remove the sunroof module and window from the vehicle and place the glass side down on a
clean bench.
Tip The sunroof window can now be manually moved forward or backward.
6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of
the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the
sunroof frame. If the
sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10942
8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if
no adhesive has been used. If adhesive has been
used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner,
P/N 08984, or equivalent, to clean the roof panel.
9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare
edges of the roof panel opening for the sunroof
module. This grease is recommended for use on any bare edges around the sunroof opening. An
acid brush can be used to apply the grease.
10. A caulk gun applicator will be needed to apply the adhesive (1).
Tip You may want to use some disposable gloves to keep the adhesive from getting onto your
hands.
11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame
assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install
the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame
assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Manually push the sunroof window to the full open position. This will allow the window, motors
and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement
in SI. 18. Verify the proper operation of the sunroof.
19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade
while using a 3M(TM) General Purpose Cleaner,
P/N 08984, or equivalent, as shown in the graphic above.
20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover.
Refer to Sunroof Front Trim Cover Replacement in SI.
Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open
the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are
installed properly.
22. Install the outer trim cover and four screws.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10943
Tighten Tighten the screws to 1 Nm (9 lb in).
Condition 2
A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the
window weather seal (4).
Cause 2
The seal on the upper sunroof frame assembly may not have enough sealant under the seal.
Correction 2
Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip
sealing flange located in the upper sunroof frame.
Condition 3
A leak from the sunroof window glass and sunroof window seal.
Cause 3
The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass
to seal properly.
Correction 3
Replace the sunroof window seal following the steps below:
1. Open the sunshade to the full open position.
2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal
Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10944
Condition 4
A leak from around the sunroof glass holder clip, known as a "blow out clip" (1).
Cause 4
A lack of adhesive sealant under the sunroof window holder clip.
Correction 4
Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the
upper frame clip using the steps below.
1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove
the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two
screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the
two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to
the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws.
Tighten Tighten the two screws to 1 Nm (9 lb in).
Important The chamfered edge of the gear goes toward the motor when reinstalling the gear.
10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws.
Tighten Tighten the screw to 2 Nm (18 lb in).
13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install
the sunroof motor assembly. 15. Install the sunroof motor screws and tighten.
Tighten Tighten the screws to 3 Nm (27 lb in).
16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim
cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and
four screws.
Tighten Tighten the screws to 1 Nm (9 lb in).
Waterleak Odor in Vehicle
Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles.
Dry out any wet components. Refer to Floor Carpet Drying in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: >
07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10945
Parts Information
To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144
from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to
place orders. The dealer also has the option to complete a referral request form to purchase the
product through a local supplier.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > Page 10946
Sunroof / Moonroof Weatherstrip: Service and Repair
Sunroof Window Seal Replacement
Removal Procedure
1. Open the sunshade to the full open position.
2. Remove the sunroof window seal (1) from the upper frame (2).
1. Carefully remove the old seal. 2. Open the sunroof window completely when working along the
front and sides. 3. Move the sunroof window into the maximum tilt position when working on the
rear side.
3. Remove the sunroof window seal from the upper frame.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > Page 10947
4. Remove all traces of sealant from around the inside upper frame groove to prevent leaks.
5. Clean the upper frame as follows, clean around the inside surface and edges with a 50/50
mixture of isopropyl alcohol and water by volume on a
dampened lint free cloth.
Installation Procedure
1. Install a adhesive sealant bead around the outside (1) of the groove of the upper frame 2 mm
(1/16 in) thick. 2. Install a adhesive sealant bead only along the front (2), on the inside of the
groove 2 mm (1/16 in) thick.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > Page 10948
Important: Put the seam of the sunroof window seal in the front under the window holder.
This is done to prevent tension in the seal.
3. Place the new sunroof window seal in the frame without pressure.
4. Install the front center under the window holder and push the sunroof window seal from the sides
to the rear only 1 mm (1/32 in) into the groove.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > Page 10949
5. Install the sunroof window seal entirely into the groove, the seal Must be kept flush fitted in the
frame.
6. Remove excessive adhesive sealant from around the sunroof window seal.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component
Information > Technical Service Bulletins > Page 10950
7. The sunroof must remain open until the adhesive sealant is dry.
* Check the curing time on the adhesive sealant.
* If the sunroof window has to be close after repair , it is advisable to apply a strip of masking tape
in the front center over the seal before closing. This is done to prevent the seal from pulling out of
the groove,
* When the repairs are completed and cured, water test the vehicle to ensure no leaks.
8. Verify operations of the sunroof window.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations
Brake Switch (Cruise Control): Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations >
Page 10955
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations >
Page 10956
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations >
Page 10957
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations >
Page 10958
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments
Clutch Switch: Adjustments
Clutch Pedal Cruise Control Release Switch Adjustment
1. Disconnect the clutch release switch electrical connector (2).
2. Rotate the clutch release switch (4) counterclockwise, allowing the retainer (5) to release. 3. Pull
the clutch pedal to full stop. 4. While holding the clutch pedal at full stop, push the switch (4) inward
fully until the switch body contacts the clutch pedal arm.
At this point the plunger in the switch (4) should be pushed in.
5. Rotate the switch (4) clockwise until a "click" is heard.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments >
Page 10962
6. Connect the clutch release switch electrical connector (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments >
Page 10963
Clutch Switch: Service and Repair
Clutch Pedal Cruise Control Release Switch Replacement
Removal Procedure
1. Disconnect the clutch release switch electrical connector (2).
2. Complete the following in order to remove the clutch release switch (4) from the clutch pedal
bracket (1):
1. Rotate the switch (4) counterclockwise. 2. Pull the switch (4) from the retainer (5). 3. Push the
locking tabs inward to release the retainer (5).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments >
Page 10964
1. Slide only the clutch release switch retainer (5) into the clutch pedal bracket (1), until the locking
tabs are fully engaged. 2. Adjust the clutch release switch. Refer to Clutch Pedal Cruise Control
Release Switch Adjustment (See: Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams
Cruise Control Switch: Diagrams
Component Connector End Views
Cruise Control Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page
10968
Cruise Control Switch: Adjustments
Cruise Release Switch Adjustment
1. Disconnect the cruise control release switch electrical connector (1).
2. Rotate the cruise release switch counterclockwise, allowing the retainer to release. 3. Pull the
brake pedal rearward to full stop. 4. While holding the brake pedal in position rearward, push the
switch inward fully until the switch body contacts the brake pedal arm.
At this point the plunger in the switch should be pushed in.
5. Rotate the switch clockwise until a "click" is heard.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page
10969
6. Connect the cruise control release switch electrical connector (1). 7. The switch is properly
adjusted when there is 7 mm (0.28 in) clearance between the end of the barrel and the striker
plate.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page
10970
Cruise Control Switch: Service and Repair
Cruise Control Release Switch Replacement
Removal Procedure
1. Disconnect the electrical connector from the cruise release switch. 2. Complete the following in
order to remove the cruise release switch from the brake pedal bracket:
1. Rotate the switch counter clockwise. 2. Pull the switch from the retainer. 3. Push the locking tabs
inward to release the retainer.
Installation Procedure
1. Connect the electrical connector to the cruise release switch.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page
10971
2. Adjust the cruise release switch. Refer to Cruise Release Switch Adjustment (See: Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations
Brake Switch (Cruise Control): Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Page 10976
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Page 10977
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Page 10978
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Page 10979
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Adjustments
Clutch Switch: Adjustments
Clutch Pedal Cruise Control Release Switch Adjustment
1. Disconnect the clutch release switch electrical connector (2).
2. Rotate the clutch release switch (4) counterclockwise, allowing the retainer (5) to release. 3. Pull
the clutch pedal to full stop. 4. While holding the clutch pedal at full stop, push the switch (4) inward
fully until the switch body contacts the clutch pedal arm.
At this point the plunger in the switch (4) should be pushed in.
5. Rotate the switch (4) clockwise until a "click" is heard.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Adjustments > Page 10983
6. Connect the clutch release switch electrical connector (2).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Component Information > Adjustments > Page 10984
Clutch Switch: Service and Repair
Clutch Pedal Cruise Control Release Switch Replacement
Removal Procedure
1. Disconnect the clutch release switch electrical connector (2).
2. Complete the following in order to remove the clutch release switch (4) from the clutch pedal
bracket (1):
1. Rotate the switch (4) counterclockwise. 2. Pull the switch (4) from the retainer (5). 3. Push the
locking tabs inward to release the retainer (5).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Adjustments > Page 10985
1. Slide only the clutch release switch retainer (5) into the clutch pedal bracket (1), until the locking
tabs are fully engaged. 2. Adjust the clutch release switch. Refer to Clutch Pedal Cruise Control
Release Switch Adjustment (See: Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams
Cruise Control Switch: Diagrams
Component Connector End Views
Cruise Control Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Page 10989
Cruise Control Switch: Adjustments
Cruise Release Switch Adjustment
1. Disconnect the cruise control release switch electrical connector (1).
2. Rotate the cruise release switch counterclockwise, allowing the retainer to release. 3. Pull the
brake pedal rearward to full stop. 4. While holding the brake pedal in position rearward, push the
switch inward fully until the switch body contacts the brake pedal arm.
At this point the plunger in the switch should be pushed in.
5. Rotate the switch clockwise until a "click" is heard.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Page 10990
6. Connect the cruise control release switch electrical connector (1). 7. The switch is properly
adjusted when there is 7 mm (0.28 in) clearance between the end of the barrel and the striker
plate.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Page 10991
Cruise Control Switch: Service and Repair
Cruise Control Release Switch Replacement
Removal Procedure
1. Disconnect the electrical connector from the cruise release switch. 2. Complete the following in
order to remove the cruise release switch from the brake pedal bracket:
1. Rotate the switch counter clockwise. 2. Pull the switch from the retainer. 3. Push the locking tabs
inward to release the retainer.
Installation Procedure
1. Connect the electrical connector to the cruise release switch.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Page 10992
2. Adjust the cruise release switch. Refer to Cruise Release Switch Adjustment (See: Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions
Cigarette Lighter: Diagram Information and Instructions
Master Electrical Schematic Icons
Master Electrical Schematic Icons
Electrical Schematic Symbols
Electrical Schematic Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Vehicle Zoning Strategy
Vehicle Zoning Strategy
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
corresponds to where they are located in the vehicle. The following table explains the numbering
system.
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Cigarette Lighter: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint
Systems/Service Precautions/SIR Warning).
Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and
causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component
damage, is identified as an OBD II circuit.
Do not connect aftermarket accessories into the following circuits:
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General
Diagnostics)
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* Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics)
* Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General
Diagnostics)
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and
Inspection/Component Tests and General Diagnostics). Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the
component operation. With the engine running, move related connectors and wiring while
monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: Testing and
Inspection/Component Tests and General Diagnostics).
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
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Information > Diagrams > Diagram Information and Instructions > Page 11046
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the frequency of a signal.
Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
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* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
Measuring Voltage Drop
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Front probe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have
been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is
the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to
use the proper test adapter may result in damage to the terminal being tested and improper
diagnosis.
Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical
center is J-35616-35. Using any other tool or adapter may damage the terminal being tested.
Refer to the following table as a guide in selecting the correct test adapter for front probing
connectors:
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Backprobe
Note:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list
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may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability
to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios.
The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot
stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Note: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Special Tools
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General
Diagnostics)
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can
monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX)
values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and
General Diagnostics) for information on connecting the J 39200 to the circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order
to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and
Inspection/Component Tests and General Diagnostics).
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 V or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 V, an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests
and General Diagnostics) in order to duplicate the conditions required, in order to verify the
customer concern.
* Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and
General Diagnostics) for test procedures to detect intermittent open, high resistance, short to
ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and
General Diagnostics) for advanced intermittent
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diagnosis and Vehicle Data Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General
Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and
Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics).
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and
Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See:
Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System
Diagram/Ground Distribution Schematics).
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
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- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component
Tests and General Diagnostics) in order to duplicate the conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests
and General Diagnostics).
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Note: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to Control
Module References (See: Testing and Inspection/Programming and Relearning) for replacement,
setup, and programming.
Testing for Short to Ground
Testing for Short to Ground
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to
one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
Note: Circuits which include any solid state control modules, such as the powertrain control module
(PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the
J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM.
This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the
presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: Testing and
Inspection/Component Tests and General Diagnostics).
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Special Tools
J 35616-200 Test Light - Probe Kit
Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test
Probe Caution).
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
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The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Special Tools
J 36169-A Fused Jumper Wire
Note: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the
inside of the connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
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3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
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5. Use a small flat-blade tool to remove TPA from the connector.
6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
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Note: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
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5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of
the connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage the
terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General
Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and
General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General
Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests
and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and
Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W)
(See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors
(Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi
Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)
* Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and
General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component
Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and
Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See:
Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors
(102-Way Inline) (See: Testing and Inspection/Component Tests and General
Diagnostics)Tyco/AMP Connectors (Seat) (See:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR)
(See: Testing and Inspection/Component Tests and General Diagnostics)
* Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General
Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General
Diagnostics)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying
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marks that are unique to that connector supplier. Most of these identify marks are hard to find or
see. Check the connector carefully and refer to the information below for pictures and descriptions
of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
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* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
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* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
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Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
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Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
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View of another type of Micro 64 connector.
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
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View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
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Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the
tool may break.
6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the
connector. See the release tool cross reference in
the Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
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Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
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1. Disconnect the connector from the component.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
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6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
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8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the
back of the connector. Always remember never
use force when pulling a terminal out of a connector. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
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1. Cut the wire as close to the terminal as possible.
Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
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Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire.
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4. Solder the crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing
and Inspection/Component Tests and General Diagnostics).
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
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5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and
Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Terminated Lead Repair
1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice
sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See:
Testing and Inspection/Component Tests and General Diagnostics).
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1).
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2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to
the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the
wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Note: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: Testing and
Inspection/Component Tests and General Diagnostics).
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
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body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wire dress cover locking tab.
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5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
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8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
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The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Glow Plug Control Module)
Kostal Connectors (Glow Plug Control Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
Note: The front TPA cannot be removed from the connector. Only move it to the preset position.
6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately
0.125 in. (3 mm).
7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
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8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the
terminal release cavity. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors (Transmission)
Kostal Connectors (Transmission)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
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1. While depressing the lock, twist and remove the connector from the component.
2. Locate the terminal position assurance (TPA).
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Note: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
3. Use a small flat-blade tool to push the TPA until it bottoms out.
4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as
shown in the graphic. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Terminal Replacement Procedure
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After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. Locate the terminal position assurance (TPA).
4. Use a small flat-blade tool to push the TPA until it bottoms out.
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5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body
when viewed.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
2. Slide the lever lock forward while pressing down on the lever lock release tab.
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3. The lever should be in the full forward position.
4. Disconnect the connector from the component.
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5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
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8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
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3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
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6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are
the 2 center rows of cavities on one half of the
connector.
7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull
the wire out of the back of the connector. Always
remember never use force when pulling a terminal out of a connector. See the release tool cross
reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool
cross reference in the Reference Guide of the
J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (Seat)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Grasp the locking slide lever and pull outward from the end of the connector.
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2. As the slide lever is pulled out the mating connector is lifted from the seated position.
3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body.
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4. Pull the TPA from the connector body.
Note: TPA is keyed and can only be inserted in one direction.
5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover
locking tab.
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6. With the lock tab released, lift the connector wire dress cover from the connector body.
7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the
terminal to be removed to release the lock tabs and pull
the terminal out of the connector body.
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8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the
terminal release tang access panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A into the terminal release tang access slot located behind the access
panel of the connector and press down on the terminal
while carefully pulling the terminal out of the connector. Always remember never use force when
pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire
procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (SIR)
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Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
1. Using your thumbs press down and slide the red CPA away from the connector lever.
2. Using your thumb press down on the locking tab and move the lever to the released position.
3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs.
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4. Pivot connector wire dress cover while removing from the connector body.
5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector
body.
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6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to
the terminal and depress the lock tab and remove
the rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Note: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool
into the terminal release cavity. For the smaller
terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal
release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (102-Way Inline)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
View of a typical connector in the assembled position.
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1. Pull the locking lever to the 90 degree position from the connector body.
2. With the locking lever in the 90 degree position and the male connector body separated, it can
be slid outward for removal.
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3. Slide the male connector body out away from the guide plates.
4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
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5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
8. The female connector body may have an additional connector hooked to the edge of the body.
Use terminal release tool 12094430 or equivalent to
release the locking tab and slide the connector off the female body.
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9. Move the locking lever 180 degrees from the connected position.
10. With the locking lever in the 180 degree position the guide plates can be removed from the
connector body.
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11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body.
Note: During assembly the TPA will not fully seat if any terminal is not fully seated.
12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the
connector body cavity.
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13. Terminal plate will bind slightly on each corner.
14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the
terminal to be removed to release the lock tabs and
pull the terminal out of the connector body.
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17. Press the terminal plate back into the female connector to the preset position. The plate will
bind slightly on each corner.
18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears
on the locking lever.
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19. Slide the male connector body back inward toward the guide plates.
20. With the locking lever in the 90 degree position and the male connector body connected, it can
be slid inward for assembly.
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21. Move the lever into the locked position or in the assembled position. This will pull the male
connector down into the female connector.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
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1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be
removed. Ensure that the pointed on the end of the tool is
facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic
terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to
ensure that the correct release tool is used.
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6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Note: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload
protection.
Flat Wire Repairs
Flat Wire Repairs
Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
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GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* Dura Seal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool
* J 38125-5 Ultra Torch Special Tool
The Dura Seal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Note: When making a repair to any GMLAN network, the original wire length after the repair must
be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation).
GMLAN Connector Terminal Repair
Note: A service terminal can be used to replace damaged connector terminals for both high speed
and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high
speed system with twisted pair wires, do not untwist the wires more than necessary to make the
repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
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Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the Dura Seal splice sleeves on all types of insulation except coaxial.
* Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
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6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Special Tools
J-38125 Terminal Repair Kit
Caution: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to
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repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a
clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction
of the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* Dura Seal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
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Note: You must perform the following procedures in the order listed. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the Dura Seal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in
the proper color nest of the Splice Crimp Tool.
The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 11159
8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest.
9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 11160
13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General
Diagnostics) and follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 11161
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals.
Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must
obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 11162
Note: You must perform the following procedures in the listed order. Repeat the procedure if any
wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 11163
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Sleeves
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 11164
Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
Description
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 11165
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that
the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold
the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal
splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the
barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper
handles will not open until the proper amount of
pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector
to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode
attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 11166
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact
with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and
General Diagnostics)
* Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General
Diagnostics)
* Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General
Diagnostics)
* SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General
Diagnostics)
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 11167
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 11168
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 11169
Cigarette Lighter: Electrical Diagrams
Cigar Lighter/Power Outlet Schematics
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Description and Operation
Compass: Description and Operation
Compass Calibration and Magnetic Variance
Compass Calibration
Before calibrating the compass, drive the vehicle to an open area that is magnetically clean or free
of large metallic objects such as high tension power lines or large steel buildings. Verify there are
no magnetized roof antennas, magnets on or hanging from the mirror, or any other magnetized
objects on the inside or outside of the vehicle close to the mirror.
1. Start the engine.
Important: Before calibrating the compass, make sure the mirror has the correct zone number.
Refer to Compass Magnetic Variation Adjustment.
2. Press and hold the switch for the compass, which may be depicted as compass/temperature or
COMP, depending on the type of mirror on the
vehicle, until the letter "C" is displayed.
3. Drive the vehicle in circles at a speed of less than 8 km/h (5 mph) until the "C" is replaced by a
proper vehicle heading. The calibration procedure
is now complete.
Compass Magnetic Variation Adjustment
Magnetic variation adjustments are required when the compass displays a constant error in
heading. Variation is the difference between magnetic north and true north due to geographical
location.
World Magnetic Variation Map
1. Locate your current geographic location on the World Magnetic Variation Map. 2. Turn ON the
ignition, with the engine OFF. 3. Press and hold the switch for the compass, which may be depicted
as compass/temperature or COMP, depending on the type of mirror on the
vehicle, until a zone number appears on the compass display.
4. Release and press the switch again until the desired zone number appears. 5. Release and wait
4 seconds. The display will return to a compass heading. The variance procedure is now complete.
6. Calibrate the compass. Refer to Compass Calibration mentioned above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air
Bag(s) Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations).
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Warning
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR
deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power
to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG
warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See:
Diagrams/Electrical Diagrams/Air Bag Systems) or
Electrical Center Identification Views (See: Maintenance/Fuses and Circuit
Breakers/Fuse/Application and ID).
4. Wait 1 minute before working on the system.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air
Bag(s) Arming and Disarming > System Information > Service and Repair > Page 11177
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to
SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical
Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and
ID).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to
Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
4. Wait 1 minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer
to Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component
Information > Locations > Harness Routing Views
Dimmer Switch: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component
Information > Locations > Harness Routing Views > Page 11182
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component
Information > Locations > Harness Routing Views > Page 11183
Dimmer Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component
Information > Locations > Page 11184
Dimmer Switch: Diagrams
Component Connector End Views
Headlamp and Panel Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp >
Component Information > Description and Operation
Door/Trunk Ajar Indicator/Lamp: Description and Operation
Door Ajar Indicator Description and Operation
Door Ajar Indicator
The instrument panel cluster (IPC) illuminates the door ajar indicator when the body control module
(BCM) detects any of the 4 vehicle doors is open. The IPC receives a class 2 message from the
BCM requesting illumination. The IPC sends a class 2 message to the radio in order to activate an
audible warning.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Harness Routing Views
Door Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Harness Routing Views > Page 11192
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Harness Routing Views > Page 11193
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Left Rear Door Harness Routing (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Harness Routing Views > Page 11194
1 - Speaker - Left Rear Door 2 - X312 (Body Harness to Left Rear Door Harness) 3 - X316 (Body
Harness to Left Rear Door Harness) 4 - Seat Belt Pretensioner - Left Front 5 - Door Jamb Switch Driver
Right Rear Door Harness Routing (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Harness Routing Views > Page 11195
1 - Speaker - Right Rear Door 2 - Door Jamb Switch - Front Passenger 3 - Seat Belt Pretensioner Right Front 4 - X317 (Body Harness to Right Rear Door Harness) 5 - X311 (Body Harness to Right
Rear Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Harness Routing Views > Page 11196
Door Switch: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Left B-Pillar Components (Regular Cab)
1 - Door Jamb Switch - Driver
Left B-Pillar and C-Pillar Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Harness Routing Views > Page 11197
1 - Door Jamb Switch - Left Rear 2 - Door Jamb Switch - Driver
Right B-Pillar Components (Regular Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Harness Routing Views > Page 11198
1 - Door Jamb Switch - Passenger
Right B-Pillar and C-Pillar Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Harness Routing Views > Page 11199
1 - Door Jamb Switch - Right Rear 2 - Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Harness Routing Views > Page 11200
Door Switch: Locations Door Component Views
Door Component Views
Left Rear Door Frame Components (Extended Cab)
1 - Door Jamb Switch - Driver
Right Rear Door Frame Components (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Harness Routing Views > Page 11201
1 - Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Page 11202
Door Switch: Diagrams
Component Connector End Views
Door Jamb Switch - Driver
Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Page 11203
Door Jamb Switch - Left Rear (Crew Cab)
Door Jamb Switch - Right Rear (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Page 11204
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Page 11205
Door Switch: Service and Repair
Door Jamb Switch Replacement
Removal Procedure
1. Open the door. 2. Remove the screw retaining the door jamb switch (1) to the body. 3. Remove
the door jamb switch (1) from the body. 4. Disconnect the electrical connector from the switch.
Installation Procedure
1. Connect the electrical connector to the door jamb switch (1). 2. Install the door jamb switch (1) to
the body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information
> Locations > Page 11206
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the screw retaining the door jam switch to the body.
Tighten the door jamb switch screw to 1.5 Nm (13 lb in).
4. Close the door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Description and Operation
Driver/Vehicle Information Display: Description and Operation
Driver Information Center (DIC) Description and Operation
Driver Information Center (DIC)
The driver information center (DIC) consists of a double line 14 character display placed in the
lower center area of the instrument panel cluster (IPC). The DIC will display vehicle information,
configuration, and warning parameters to the driver.
The display parameters are cycled, changed, and acknowledged using a control stem. Pressing the
stem for 1 second will display the DIC options. Pressing the stem for more than 2 seconds will
select an option.
DIC Displays
The driver information center (DIC) parameters are displayed by order of priority as follows (from
highest to lowest) :
* Service Diagnostics
* Feature Programming
* Driver Warnings
* Vehicle Information
Vehicle Information
Vehicle information provides feedback to the driver on vehicle performance, mileage, maintenance
or related information. When the English/Metric status changes, any applicable vehicle information
data values will also change.
Odometer
The odometer is capable of displaying values from 0-999,999 KM or MI. If the ignition is in the OFF
or UNLOCK/ACC position, the odometer can be displayed by pressing the trip/reset switch. The
odometer will remain displayed for 5 seconds.
Trip Odometers
The trip odometer is capable of displaying values from 0-9999.9 KM or MI. When the maximum
value is reached, the trip odometer will roll over to 0.0. Holding the control stem for greater than 4
seconds while the trip odometer is displayed will reset the displayed trip odometer to 0.0 upon
release of the stem. The trip odometer will remain displayed after being reset.
Engine Oil Life
Engine Oil Life percentage values are based on serial data messages to the instrument panel
cluster (IPC). The IPC requests this value when Engine Oil Life is selected on the DIC. Engine Oil
Life is capable of displaying values from 0 to 100%. Pressing the control stem for longer than 2
seconds while Engine Oil Life is displayed on the DIC will reset the value to 100%. An audible
warning will sound confirming that the system has been reset. Display appears as OIL LIFE:
XXX%.
Display Language
The driver information center (DIC) is capable of displaying messages in more than one language.
The DIC language selection procedure is as follows:
1. With the engine OFF, turn the key to ON, but do not start the engine. 2. Close all doors so the
DOORS message does not display in the DIC. 3. Momentarily press and release the trip reset stem
until the current language is displayed: English, French or Spanish. 4. To select a different
language, press and hold the trip reset stem until the next language appears. 5. Repeat Step 4 until
the desired language is displayed. Once the desired language is shown on the DIC display, the
language is set. 6. To exit language selection, momentarily press and release the trip stem. All DIC
messages will now display in the language selected.
Feature Programming
Refer to Personalization Description and Operation (See: Accessories and Optional
Equipment/Description and Operation/Personalization Description and Operation).
Driver Warnings
For the list of Driver Warnings, refer to Indicator/Warning Message Description and Operation
(See: Description and Operation/Indicator/Warning Message Description and Operation).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams
Fuel Gauge Sender: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air
Bag(s) Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations).
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Warning
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR
deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power
to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG
warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See:
Diagrams/Electrical Diagrams/Air Bag Systems) or
Electrical Center Identification Views (See: Maintenance/Fuses and Circuit
Breakers/Fuse/Application and ID).
4. Wait 1 minute before working on the system.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air
Bag(s) Arming and Disarming > System Information > Service and Repair > Page 11217
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to
SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical
Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and
ID).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to
Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
4. Wait 1 minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer
to Battery Negative Cable Disconnection and Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair).
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips
Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System
Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
11222
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
11223
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
11224
Customer TPMS Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
11225
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
11226
Frequently Asked Questions
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator
> Component Information > Service and Repair
Maintenance Required Lamp/Indicator: Service and Repair
SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR
If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON"
indicator. This indicator is not a maintenance indicator and does not mean a maintenance service
is required.
For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information
refer to Malfunction Indicator Lamp.
For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp >
Component Information > Testing and Inspection
Malfunction Indicator Lamp: Testing and Inspection
Malfunction Indicator Lamp (MIL) Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category.
Circuit/System Description
Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module
(ECM) turns the MIL ON by grounding the MIL control circuit.
Reference Information Schematic Reference
* Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Cluster
Schematics)
* Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams)
Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views) Electrical Information
Reference
* Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics)
* Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
* Testing for Intermittent Conditions and Poor Connections (See: Testing and
Inspection/Component Tests and General Diagnostics)
* Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics)
Scan Tool Reference
Control Module References (See: Testing and Inspection/Programming and Relearning)for scan
tool information
Circuit/System Verification
Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool.
Circuit/System Testing
1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition
ON, verify that a test lamp illuminates between the ignition circuit and ground.
‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high
resistance. If the circuit tests normal and the
ignition circuit fuse is open, replace the IPC.
3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON
and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the
commanded states.
‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests
normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to
voltage or an open/high resistance. If the circuit tests normal, replace the
ECM.
5. If all circuits test normal, replace the IPC.
Repair Instructions
Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Verification Tests and Procedures) after completing the diagnostic procedure.
* Instrument Cluster Replacement (See: Instrument Cluster / Carrier/Service and Repair/Instrument
Cluster Replacement)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp >
Component Information > Testing and Inspection > Page 11233
* Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM
replacement, setup, and programming
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide
Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide
INFORMATION
Bulletin No.: 07-08-49-020D
Date: December 06, 2010
Subject: IPC Odometer Programming Method Quick Reference Guide
Models:
2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3
2005-2009 Saab 9-7X
Attention:
This bulletin applies to vehicles sold in the U.S. and Canada Only.
Supercede: This bulletin is being revised to add information for the 2011 model year and add new
2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and
Accessories).
The purpose of this bulletin is to provide a reference guide to help identify which season odometer
programming method to use after replacing the instrument panel cluster (IPC). The three season
odometer programming methods in use today are listed below. In addition, this reference guide lists
the component where the season odometer value is stored. The season odometer value may be
stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM),
also commonly called a body control module (BCM).
Season Odometer Programming Methods in Use Today
1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup
at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2
is used to set up a replacement BCM, which includes loading the odometer value that is displayed
and stored in the IPC. A
replacement IPC will display the previously stored vehicle odometer value, communicated from the
BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as
part of the BCM programming procedure. It is not a stand-alone event.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 11238
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 11239
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 11240
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp >
Component Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
GM Oil Life System Resetting
The vehicle has a computer system that has a change engine oil message, indicating when to
change the engine oil and filter. This is based on engine revolutions and engine temperature, and
not on mileage. Based on driving conditions, the kilometers or mileage at which an oil change will
be indicated can vary considerably. For the oil life system to work properly, the system must be
reset every time the oil is changed.
When the system has calculated that oil life has been diminished, it will indicate that an oil change
is necessary. The change engine oil message will come on. The oil must be changed as soon as
possible. It is possible that, if the vehicle is driven under the best conditions, the oil life system may
not indicate that an oil change is necessary for over a year. However, the engine oil and filter must
be changed at least once a year and at this time the system must be reset. If the system is ever
reset accidentally, the oil must be changed at 3,000 miles (5 000 km) since the last oil change.
Remember to reset the oil life system whenever the oil and filter is changed.
Resetting Procedure
1. Turn the ignition to RUN with the engine OFF. 2. Press and release the reset stem in the lower
center of the instrument panel (I/P) cluster until the OIL LIFE message is displayed. 3. Once the
alternating OIL LIFE and RESET messages appears in the display, press and hold the reset stem
until several beeps sound. This confirms
the OIL LIFE system has been reset.
4. Turn the key to lock.
If the CHANGE OIL message comes back on when you start the engine, the ENGINE OIL LIFE
system has not reset. Repeat the procedure.
Alternate Method
1. Turn the ignition key to RUN with the engine off. 2. Fully press the release the accelerator pedal
3 times within 5 seconds. Several beeps sound. This confirms the oil life system has been reset. 3.
If the CHANGE/OIL message comes back on when you start the engine, the engine oil life system
has not been reset. Repeat the procedure.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations
Oil Pressure Sender: Locations
Powertrain Component Views
Engine - Left (LH8)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative
Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition
Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations > Page 11247
Oil Pressure Sender: Diagrams
Component Connector End Views
Engine Oil Pressure (EOP) Sensor (LH8)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display >
Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment
Component Views
Outside Temperature Display Sensor: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Front of the Engine Compartment Components
1 - Ambient Air Temperature (AAT) Sensor (DF8) 2 - Horn Assembly 3 - Inflatable Restraint Front
End Sensor - Left 4 - Inflatable Restraint Front End Sensor - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display >
Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment
Component Views > Page 11253
Outside Temperature Display Sensor: Locations Harness Routing Views
Harness Routing Views
Forward Lamp Harness Routing
1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn
Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right
11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low
Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body
Harness) 16 - X103 (Forward Lamp Harness to Body Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display >
Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment
Component Views > Page 11254
17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness
(TT5) 19 - Forward Lamp Harness (-TT5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display >
Outside Temperature Display Sensor > Component Information > Locations > Page 11255
Outside Temperature Display Sensor: Service and Repair
Ambient Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air inlet grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and
Repair). 2. Disconnect the electrical connector to the ambient air temperature sensor.
3. Release the tabs (1) retaining the sensor to the radiator support bracket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display >
Outside Temperature Display Sensor > Component Information > Locations > Page 11256
4. Remove the sensor (1) from the radiator support bracket.
Installation Procedure
1. Position the sensor (1) to the radiator support bracket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display >
Outside Temperature Display Sensor > Component Information > Locations > Page 11257
2. Install the sensor ensuring the retaining tabs (1) are fully seated to the radiator support bracket.
3. Connect the electrical connector to the ambient air temperature sensor. 4. Install the air inlet
grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Remove the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Dashboard /
Instrument Panel/Service and Repair).
2. Remove the electrical connector.
3. Remove the park brake warning lamp switch mounting bolt.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Service and Repair > Page 11261
4. Remove the park brake warning lamp switch from the vehicle.
Installation Procedure
1. Install the park brake warning lamp switch.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the park brake warning lamp switch mounting bolt and tighten to 4 Nm (35 lb in).
3. Install the electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Service and Repair > Page 11262
4. Install the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Dashboard /
Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Dimmer Switch > Component Information > Locations > Harness Routing Views
Dimmer Switch: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Dimmer Switch > Component Information > Locations > Harness Routing Views > Page 11268
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Dimmer Switch > Component Information > Locations > Harness Routing Views > Page 11269
Dimmer Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Dimmer Switch > Component Information > Locations > Page 11270
Dimmer Switch: Diagrams
Component Connector End Views
Headlamp and Panel Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Harness Routing Views
Door Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11275
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11276
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Left Rear Door Harness Routing (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11277
1 - Speaker - Left Rear Door 2 - X312 (Body Harness to Left Rear Door Harness) 3 - X316 (Body
Harness to Left Rear Door Harness) 4 - Seat Belt Pretensioner - Left Front 5 - Door Jamb Switch Driver
Right Rear Door Harness Routing (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11278
1 - Speaker - Right Rear Door 2 - Door Jamb Switch - Front Passenger 3 - Seat Belt Pretensioner Right Front 4 - X317 (Body Harness to Right Rear Door Harness) 5 - X311 (Body Harness to Right
Rear Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11279
Door Switch: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Left B-Pillar Components (Regular Cab)
1 - Door Jamb Switch - Driver
Left B-Pillar and C-Pillar Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11280
1 - Door Jamb Switch - Left Rear 2 - Door Jamb Switch - Driver
Right B-Pillar Components (Regular Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11281
1 - Door Jamb Switch - Passenger
Right B-Pillar and C-Pillar Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11282
1 - Door Jamb Switch - Right Rear 2 - Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11283
Door Switch: Locations Door Component Views
Door Component Views
Left Rear Door Frame Components (Extended Cab)
1 - Door Jamb Switch - Driver
Right Rear Door Frame Components (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11284
1 - Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Page 11285
Door Switch: Diagrams
Component Connector End Views
Door Jamb Switch - Driver
Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Page 11286
Door Jamb Switch - Left Rear (Crew Cab)
Door Jamb Switch - Right Rear (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Page 11287
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Page 11288
Door Switch: Service and Repair
Door Jamb Switch Replacement
Removal Procedure
1. Open the door. 2. Remove the screw retaining the door jamb switch (1) to the body. 3. Remove
the door jamb switch (1) from the body. 4. Disconnect the electrical connector from the switch.
Installation Procedure
1. Connect the electrical connector to the door jamb switch (1). 2. Install the door jamb switch (1) to
the body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Door Switch > Component Information > Locations > Page 11289
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the screw retaining the door jam switch to the body.
Tighten the door jamb switch screw to 1.5 Nm (13 lb in).
4. Close the door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Diagrams
Fuel Gauge Sender: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine
Compartment Component Views
Outside Temperature Display Sensor: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Front of the Engine Compartment Components
1 - Ambient Air Temperature (AAT) Sensor (DF8) 2 - Horn Assembly 3 - Inflatable Restraint Front
End Sensor - Left 4 - Inflatable Restraint Front End Sensor - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine
Compartment Component Views > Page 11297
Outside Temperature Display Sensor: Locations Harness Routing Views
Harness Routing Views
Forward Lamp Harness Routing
1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn
Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right
11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low
Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body
Harness) 16 - X103 (Forward Lamp Harness to Body Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine
Compartment Component Views > Page 11298
17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness
(TT5) 19 - Forward Lamp Harness (-TT5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 11299
Outside Temperature Display Sensor: Service and Repair
Ambient Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air inlet grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and
Repair). 2. Disconnect the electrical connector to the ambient air temperature sensor.
3. Release the tabs (1) retaining the sensor to the radiator support bracket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 11300
4. Remove the sensor (1) from the radiator support bracket.
Installation Procedure
1. Position the sensor (1) to the radiator support bracket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 11301
2. Install the sensor ensuring the retaining tabs (1) are fully seated to the radiator support bracket.
3. Connect the electrical connector to the ambient air temperature sensor. 4. Install the air inlet
grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Parking Brake Warning Switch > Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Remove the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Dashboard /
Instrument Panel/Service and Repair).
2. Remove the electrical connector.
3. Remove the park brake warning lamp switch mounting bolt.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Page 11305
4. Remove the park brake warning lamp switch from the vehicle.
Installation Procedure
1. Install the park brake warning lamp switch.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the park brake warning lamp switch mounting bolt and tighten to 4 Nm (35 lb in).
3. Install the electrical connector.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Page 11306
4. Install the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Dashboard /
Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips
Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System
Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 11312
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 11313
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
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Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 11314
Customer TPMS Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
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Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 11315
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 11316
Frequently Asked Questions
Disclaimer
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Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System TPM Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
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Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 11329
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
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Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 11330
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
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Sensor IDs > Page 11331
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
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Sensor IDs > Page 11332
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
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13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
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Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement
Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the
vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and
Tires/Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See:
Maintenance/Wheels and Tires/Tires/Service and
Repair/Removal and Replacement).
Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the
inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
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Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page
11336
Tighten the sensor nut to 7 Nm (62 lb in).
Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting.
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels
and Tires/Tires/Service and Repair/Removal
and Replacement).
Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor
unique identification code cannot be learned into the body control module (BCM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensors internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Maintenance/Wheels and Tires/Service
and Repair).
6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor
Learn (See: Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page
11337
Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement
Tire Valve Stem Grommet Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the
vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and
Tires/Service and Repair).
Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting:
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead
from the wheel.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the outside of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See:
Maintenance/Wheels and Tires/Tires/Service and
Repair/Removal and Replacement).
Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure
Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all
residual liquid sealant from the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the
sensor grommet from the valve stem.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor
valve stem.
3. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page
11338
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 Nm (62 lb in).
Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor
damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels
and Tires/Tires/Service and Repair/Removal
and Replacement).
6. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Maintenance/Wheels and Tires/Service
and Repair).
7. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views
Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 11344
Ambient Light Sensor: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 11345
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page
11346
Ambient Light Sensor: Diagrams
Component Connector End Views
Ambient Light Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page
11347
Ambient Light Sensor: Service and Repair
Ambient Light Sensor Replacement
Removal Procedure
1. Carefully use a flat-bladed tool, and remove the sensor from the upper portion of the instrument
panel (I/P).
2. Disconnect the electrical connector (2) from the sensor ensuring the connector does NOT fall
through the hole in the I/P. 3. Remove the sensor from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page
11348
1. Connect the electrical connector (2) to the sensor.
2. Align the sensor to the I/P for installation. 3. Apply downward pressure to the sensor head in
order to seat the sensor to the I/P.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations
Backup Lamp Switch: Locations
Powertrain Component Views
Right Side of the Transmission Components (MA5)
1 - Backup Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Page 11353
Backup Lamp Switch: Diagrams
Component Connector End Views
Backup Lamp Switch (MA5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Page 11354
Backup Lamp Switch: Service and Repair
Backup Lamp Switch Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the backup lamp switch electrical connector (1) at the pigtail. 3. Open the tie strap
securing the pigtail to the transmission.
4. Remove the backup lamp switch with the aluminum washer.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Page 11355
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
1. Install the backup lamp switch with a NEW aluminum washer into the transmission case.
Tighten the backup lamp switch to 44 Nm (32 lb ft).
2. Secure the pigtail to the transmission with the tie strap. 3. Connect the backup lamp switch
electrical connector (1) at the pigtail. 4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information >
Service and Repair
Backup Light Bulb: Service and Repair
Backup Lamp Bulb Replacement
Removal Procedure
1. Open the tailgate. 2. Remove the screws (1) from the tail lamp assembly. 3. Remove the lamp
assembly.
4. Remove the tail lamp and backup lamp sockets, depressing the locking tab and rotating
counterclockwise. 5. Remove the bulbs from the backup lamp sockets.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information >
Service and Repair > Page 11359
1. Install the bulbs to the backup lamp sockets. 2. Install the backup lamp rotating clockwise until
the locking tab is fully seated.
3. Press the tail lamp to the rear body panel until fully seated.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the tail lamp screws (1) to the tail lamp.
Tighten the tail lamp screws (1) to 3 Nm (26 lb in).
5. Close the tailgate.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > Recalls for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON
Technical Service Bulletin # 09049A Date: 110314
Recall - Brake Lamps Inoperative/Continuously ON
SAFETY
Bulletin No.: 09049A
Date: March 14, 2011
Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination
Models:
2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida,
Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas,
U.S. Virgin Islands, Utah
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s). Please discard all copies of bulletin 09049, issued July 2010.
Condition
General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch. Performance of the brakes is not
affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could
become inoperative.
Correction
Dealers are to install a new brake lamp switch assembly.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles
registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New
Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these
VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate
Vehicle History link. Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report
available if they have no involved vehicles currently assigned.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > Recalls for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON
> Page 11369
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
Parts required to complete this recall are to be obtained from General Motors Customer Care and
Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal
orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts
should be ordered on a CSO = Customer Special Order.
Service Procedure
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Customer Reimbursement - For GM US
All customer requests for reimbursement of previously paid repairs for the recall condition will be
handled by the Customer Assistance Center, not by dealers.
Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section
6.1.12, for specific procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs for the recall condition are to be
submitted to the dealer by August 31, 2011.
All reasonable customer paid receipts should be considered for reimbursement. The amount to be
reimbursed will be limited to the amount the repair would have cost if completed by an authorized
General Motors dealer.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a
description of the repair, and the person or entity performing the repair.
Claims for customer reimbursement on previously paid repairs are to be submitted as required by
WINS.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement verification.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > Recalls for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON
> Page 11370
* The amount identified in the "Net Item" column should represent the dollar amount reimbursed to
the customer.
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
included with this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the attached sample letter.
Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions)
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a
recall of this type must be adequately repaired within a reasonable time after the customer has
tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not adequately repaired
within a reasonable time, the customer may be entitled to an identical or reasonably equivalent
vehicle at no charge or to a refund of the purchase price less a reasonable allowance for
depreciation. To avoid having to provide these burdensome remedies, every effort must be made
to promptly schedule an appointment with each customer and to repair their vehicle as soon as
possible. In the recall notification letters, customers are told how to contact the US National
Highway Traffic Safety Administration if the recall is not completed within a reasonable time.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers' possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
Disclaimer
Owner Letter
Owner Letter
(Letter sent to customers in Phase 1 Notification)
Dear General Motors Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > Recalls for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON
> Page 11371
continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as
designed due to contamination in the switch. Performance of the brakes is not affected. However,
this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps
to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions
and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative.
What will we do? When parts are available after August 2, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment on or
after August 2, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the Owner Center at www.gmownercenter.com.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049
Division Owner Letter
Division Owner Letter
(Letter sent to customer in Phase 2 notification)
Dear General Motors Customer:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > Recalls for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON
> Page 11372
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
- Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work
as designed due to contamination in the switch. Performance of the brakes is not affected.
However, this condition could cause the simultaneous loss of all brake lamps or cause all of the
brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could
become inoperative.
What will we do? When parts are available after August 26, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment onor
after August 26, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
GM dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049-2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > Recalls for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or
Continuously On
Technical Service Bulletin # 09186B Date: 110314
Campaign - Brake Lamps Inoperative Or Continuously On
SPECIAL COVERAGE
Bulletin No.: 09186B
Date: March 14, 2011
Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR
CONTINUOUS ILLUMINATION
Models:
2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030.
If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010.
Condition
Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may
comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be
caused by contamination in the brake lamp switch. The performance of the brakes is not affected.
Also, if equipped, they may comment about the loss of cruise control.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 7 years or 100,000
miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership.
Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to
the customer.
For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after
September 28, 2010, are covered by this special coverage and must be submitted using the labor
operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010,
must be submitted to the Service Contract provider.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built
within the following VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable
Warranties section in the Global Warranty Management system.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > Recalls for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or
Continuously On > Page 11377
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of
these switches on their shelves. Please verify your dealer inventory before ordering additional
quantities.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter shown in this bulletin - actual divisional letter may vary slightly).
Service Procedure
Note
Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the
vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Warranty Transaction Information
Submit a claim using the table below.
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must
have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000
km, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > Recalls for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or
Continuously On > Page 11378
the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Disclaimer
Owner Letter
Owner Letter
Dear GM Customer:
As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your
satisfaction with our product is very important to us.
This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado
and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch
could cause the loss of brake lamps or continuous illumination of the brake lamps. The
performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it
may become inoperative.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the brake
lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon
vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles
(160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis
or repair for conditions other than the condition described above is not covered under this special
coverage program.
What You Should Do: Repairs and adjustments qualifying under this special coverage must be
performed by a General Motors dealer. If you believe your vehicle has the condition described
above, you may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by December 31, 2011. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
General Motors Corporation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > Recalls for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or
Continuously On > Page 11379
Enclosure
09186
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps
Inoperative/Continuously ON
Technical Service Bulletin # 09049A Date: 110314
Recall - Brake Lamps Inoperative/Continuously ON
SAFETY
Bulletin No.: 09049A
Date: March 14, 2011
Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination
Models:
2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida,
Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas,
U.S. Virgin Islands, Utah
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s). Please discard all copies of bulletin 09049, issued July 2010.
Condition
General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch. Performance of the brakes is not
affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could
become inoperative.
Correction
Dealers are to install a new brake lamp switch assembly.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles
registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New
Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these
VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate
Vehicle History link. Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report
available if they have no involved vehicles currently assigned.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps
Inoperative/Continuously ON > Page 11385
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
Parts required to complete this recall are to be obtained from General Motors Customer Care and
Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal
orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts
should be ordered on a CSO = Customer Special Order.
Service Procedure
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Customer Reimbursement - For GM US
All customer requests for reimbursement of previously paid repairs for the recall condition will be
handled by the Customer Assistance Center, not by dealers.
Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section
6.1.12, for specific procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs for the recall condition are to be
submitted to the dealer by August 31, 2011.
All reasonable customer paid receipts should be considered for reimbursement. The amount to be
reimbursed will be limited to the amount the repair would have cost if completed by an authorized
General Motors dealer.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a
description of the repair, and the person or entity performing the repair.
Claims for customer reimbursement on previously paid repairs are to be submitted as required by
WINS.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement verification.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps
Inoperative/Continuously ON > Page 11386
* The amount identified in the "Net Item" column should represent the dollar amount reimbursed to
the customer.
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
included with this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the attached sample letter.
Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions)
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a
recall of this type must be adequately repaired within a reasonable time after the customer has
tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not adequately repaired
within a reasonable time, the customer may be entitled to an identical or reasonably equivalent
vehicle at no charge or to a refund of the purchase price less a reasonable allowance for
depreciation. To avoid having to provide these burdensome remedies, every effort must be made
to promptly schedule an appointment with each customer and to repair their vehicle as soon as
possible. In the recall notification letters, customers are told how to contact the US National
Highway Traffic Safety Administration if the recall is not completed within a reasonable time.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers' possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
Disclaimer
Owner Letter
Owner Letter
(Letter sent to customers in Phase 1 Notification)
Dear General Motors Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps
Inoperative/Continuously ON > Page 11387
continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as
designed due to contamination in the switch. Performance of the brakes is not affected. However,
this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps
to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions
and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative.
What will we do? When parts are available after August 2, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment on or
after August 2, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the Owner Center at www.gmownercenter.com.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049
Division Owner Letter
Division Owner Letter
(Letter sent to customer in Phase 2 notification)
Dear General Motors Customer:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps
Inoperative/Continuously ON > Page 11388
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
- Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work
as designed due to contamination in the switch. Performance of the brakes is not affected.
However, this condition could cause the simultaneous loss of all brake lamps or cause all of the
brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could
become inoperative.
What will we do? When parts are available after August 26, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment onor
after August 26, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
GM dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049-2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps
Inoperative Or Continuously On
Technical Service Bulletin # 09186B Date: 110314
Campaign - Brake Lamps Inoperative Or Continuously On
SPECIAL COVERAGE
Bulletin No.: 09186B
Date: March 14, 2011
Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR
CONTINUOUS ILLUMINATION
Models:
2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030.
If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010.
Condition
Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may
comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be
caused by contamination in the brake lamp switch. The performance of the brakes is not affected.
Also, if equipped, they may comment about the loss of cruise control.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 7 years or 100,000
miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership.
Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to
the customer.
For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after
September 28, 2010, are covered by this special coverage and must be submitted using the labor
operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010,
must be submitted to the Service Contract provider.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built
within the following VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable
Warranties section in the Global Warranty Management system.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps
Inoperative Or Continuously On > Page 11393
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of
these switches on their shelves. Please verify your dealer inventory before ordering additional
quantities.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter shown in this bulletin - actual divisional letter may vary slightly).
Service Procedure
Note
Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the
vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Warranty Transaction Information
Submit a claim using the table below.
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must
have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000
km, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps
Inoperative Or Continuously On > Page 11394
the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Disclaimer
Owner Letter
Owner Letter
Dear GM Customer:
As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your
satisfaction with our product is very important to us.
This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado
and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch
could cause the loss of brake lamps or continuous illumination of the brake lamps. The
performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it
may become inoperative.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the brake
lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon
vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles
(160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis
or repair for conditions other than the condition described above is not covered under this special
coverage program.
What You Should Do: Repairs and adjustments qualifying under this special coverage must be
performed by a General Motors dealer. If you believe your vehicle has the condition described
above, you may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by December 31, 2011. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
General Motors Corporation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps
Inoperative Or Continuously On > Page 11395
Enclosure
09186
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON
Technical Service Bulletin # 09049A Date: 110314
Recall - Brake Lamps Inoperative/Continuously ON
SAFETY
Bulletin No.: 09049A
Date: March 14, 2011
Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination
Models:
2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida,
Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas,
U.S. Virgin Islands, Utah
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s). Please discard all copies of bulletin 09049, issued July 2010.
Condition
General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch. Performance of the brakes is not
affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could
become inoperative.
Correction
Dealers are to install a new brake lamp switch assembly.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles
registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New
Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these
VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate
Vehicle History link. Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report
available if they have no involved vehicles currently assigned.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON >
Page 11404
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
Parts required to complete this recall are to be obtained from General Motors Customer Care and
Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal
orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts
should be ordered on a CSO = Customer Special Order.
Service Procedure
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Customer Reimbursement - For GM US
All customer requests for reimbursement of previously paid repairs for the recall condition will be
handled by the Customer Assistance Center, not by dealers.
Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section
6.1.12, for specific procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs for the recall condition are to be
submitted to the dealer by August 31, 2011.
All reasonable customer paid receipts should be considered for reimbursement. The amount to be
reimbursed will be limited to the amount the repair would have cost if completed by an authorized
General Motors dealer.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a
description of the repair, and the person or entity performing the repair.
Claims for customer reimbursement on previously paid repairs are to be submitted as required by
WINS.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement verification.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON >
Page 11405
* The amount identified in the "Net Item" column should represent the dollar amount reimbursed to
the customer.
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
included with this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the attached sample letter.
Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions)
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a
recall of this type must be adequately repaired within a reasonable time after the customer has
tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not adequately repaired
within a reasonable time, the customer may be entitled to an identical or reasonably equivalent
vehicle at no charge or to a refund of the purchase price less a reasonable allowance for
depreciation. To avoid having to provide these burdensome remedies, every effort must be made
to promptly schedule an appointment with each customer and to repair their vehicle as soon as
possible. In the recall notification letters, customers are told how to contact the US National
Highway Traffic Safety Administration if the recall is not completed within a reasonable time.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers' possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
Disclaimer
Owner Letter
Owner Letter
(Letter sent to customers in Phase 1 Notification)
Dear General Motors Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON >
Page 11406
continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as
designed due to contamination in the switch. Performance of the brakes is not affected. However,
this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps
to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions
and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative.
What will we do? When parts are available after August 2, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment on or
after August 2, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the Owner Center at www.gmownercenter.com.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049
Division Owner Letter
Division Owner Letter
(Letter sent to customer in Phase 2 notification)
Dear General Motors Customer:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON >
Page 11407
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
- Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work
as designed due to contamination in the switch. Performance of the brakes is not affected.
However, this condition could cause the simultaneous loss of all brake lamps or cause all of the
brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could
become inoperative.
What will we do? When parts are available after August 26, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment onor
after August 26, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
GM dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049-2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously
On
Technical Service Bulletin # 09186B Date: 110314
Campaign - Brake Lamps Inoperative Or Continuously On
SPECIAL COVERAGE
Bulletin No.: 09186B
Date: March 14, 2011
Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR
CONTINUOUS ILLUMINATION
Models:
2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030.
If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010.
Condition
Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may
comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be
caused by contamination in the brake lamp switch. The performance of the brakes is not affected.
Also, if equipped, they may comment about the loss of cruise control.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 7 years or 100,000
miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership.
Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to
the customer.
For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after
September 28, 2010, are covered by this special coverage and must be submitted using the labor
operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010,
must be submitted to the Service Contract provider.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built
within the following VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable
Warranties section in the Global Warranty Management system.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously
On > Page 11412
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of
these switches on their shelves. Please verify your dealer inventory before ordering additional
quantities.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter shown in this bulletin - actual divisional letter may vary slightly).
Service Procedure
Note
Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the
vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Warranty Transaction Information
Submit a claim using the table below.
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must
have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000
km, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously
On > Page 11413
the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Disclaimer
Owner Letter
Owner Letter
Dear GM Customer:
As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your
satisfaction with our product is very important to us.
This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado
and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch
could cause the loss of brake lamps or continuous illumination of the brake lamps. The
performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it
may become inoperative.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the brake
lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon
vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles
(160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis
or repair for conditions other than the condition described above is not covered under this special
coverage program.
What You Should Do: Repairs and adjustments qualifying under this special coverage must be
performed by a General Motors dealer. If you believe your vehicle has the condition described
above, you may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by December 31, 2011. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
General Motors Corporation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously
On > Page 11414
Enclosure
09186
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Recalls for Brake Light Switch: > NHTSA09V310000 > Jul > 09 > Recall 09V310000: Brake Lamp Switch Defect
Brake Light Switch: Recalls Recall 09V310000: Brake Lamp Switch Defect
VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2009 GMC/Canyon
2004-2009 Isuzu/I-280 2006 Isuzu/I-290 2007-2008 Isuzu/I-350 2006 Isuzu/I-370 2007-2008
MANUFACTURER: General Motors Corp.
MFR'S REPORT DATE: July 28, 2009
NHTSA CAMPAIGN ID NUMBER: 09V310000
NHTSA ACTION NUMBER: RQ09001 COMPONENT: Exterior Lighting: Brake Lights: Switch
POTENTIAL NUMBER OF UNITS AFFECTED: 185903
SUMMARY: GM is recalling 185,903 model year 2004-2009 Chevrolet Colorado, Model year
2004-2009 GMC Canyon, model year 2006 Isuzu I-280, I-350, model year 2007-2008 Isuzu I-290,
and I-370, passenger vehicles originally sold in or currently registered in the states of Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch.
CONSEQUENCE: This condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash.
REMEDY: Dealers will inspect and replace the necessary components as specified in the recall
bulletin free of charge. GM anticipates that parts will be available by February 2010. A special
coverage for vehicles registered in all other states will be implemented in the same time frame. In
the interim, owners who experience the failure can obtain a free repair, however they will be
required to return when the new design part becomes available. Owners may contact Chevrolet at
1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or at
www.gmownercenter.com.
NOTES: GM recall No. 09049. Owners may also contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps
Inoperative/Continuously ON
Technical Service Bulletin # 09049A Date: 110314
Recall - Brake Lamps Inoperative/Continuously ON
SAFETY
Bulletin No.: 09049A
Date: March 14, 2011
Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination
Models:
2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida,
Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas,
U.S. Virgin Islands, Utah
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s). Please discard all copies of bulletin 09049, issued July 2010.
Condition
General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch. Performance of the brakes is not
affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could
become inoperative.
Correction
Dealers are to install a new brake lamp switch assembly.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles
registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New
Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these
VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate
Vehicle History link. Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report
available if they have no involved vehicles currently assigned.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps
Inoperative/Continuously ON > Page 11424
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
Parts required to complete this recall are to be obtained from General Motors Customer Care and
Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal
orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts
should be ordered on a CSO = Customer Special Order.
Service Procedure
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Customer Reimbursement - For GM US
All customer requests for reimbursement of previously paid repairs for the recall condition will be
handled by the Customer Assistance Center, not by dealers.
Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section
6.1.12, for specific procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs for the recall condition are to be
submitted to the dealer by August 31, 2011.
All reasonable customer paid receipts should be considered for reimbursement. The amount to be
reimbursed will be limited to the amount the repair would have cost if completed by an authorized
General Motors dealer.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a
description of the repair, and the person or entity performing the repair.
Claims for customer reimbursement on previously paid repairs are to be submitted as required by
WINS.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement verification.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps
Inoperative/Continuously ON > Page 11425
* The amount identified in the "Net Item" column should represent the dollar amount reimbursed to
the customer.
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
included with this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the attached sample letter.
Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions)
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a
recall of this type must be adequately repaired within a reasonable time after the customer has
tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not adequately repaired
within a reasonable time, the customer may be entitled to an identical or reasonably equivalent
vehicle at no charge or to a refund of the purchase price less a reasonable allowance for
depreciation. To avoid having to provide these burdensome remedies, every effort must be made
to promptly schedule an appointment with each customer and to repair their vehicle as soon as
possible. In the recall notification letters, customers are told how to contact the US National
Highway Traffic Safety Administration if the recall is not completed within a reasonable time.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers' possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
Disclaimer
Owner Letter
Owner Letter
(Letter sent to customers in Phase 1 Notification)
Dear General Motors Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps
Inoperative/Continuously ON > Page 11426
continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as
designed due to contamination in the switch. Performance of the brakes is not affected. However,
this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps
to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions
and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative.
What will we do? When parts are available after August 2, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment on or
after August 2, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the Owner Center at www.gmownercenter.com.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049
Division Owner Letter
Division Owner Letter
(Letter sent to customer in Phase 2 notification)
Dear General Motors Customer:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps
Inoperative/Continuously ON > Page 11427
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
- Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work
as designed due to contamination in the switch. Performance of the brakes is not affected.
However, this condition could cause the simultaneous loss of all brake lamps or cause all of the
brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could
become inoperative.
What will we do? When parts are available after August 26, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment onor
after August 26, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
GM dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049-2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps
Inoperative Or Continuously On
Technical Service Bulletin # 09186B Date: 110314
Campaign - Brake Lamps Inoperative Or Continuously On
SPECIAL COVERAGE
Bulletin No.: 09186B
Date: March 14, 2011
Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR
CONTINUOUS ILLUMINATION
Models:
2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030.
If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010.
Condition
Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may
comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be
caused by contamination in the brake lamp switch. The performance of the brakes is not affected.
Also, if equipped, they may comment about the loss of cruise control.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 7 years or 100,000
miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership.
Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to
the customer.
For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after
September 28, 2010, are covered by this special coverage and must be submitted using the labor
operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010,
must be submitted to the Service Contract provider.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built
within the following VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable
Warranties section in the Global Warranty Management system.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps
Inoperative Or Continuously On > Page 11432
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of
these switches on their shelves. Please verify your dealer inventory before ordering additional
quantities.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter shown in this bulletin - actual divisional letter may vary slightly).
Service Procedure
Note
Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the
vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Warranty Transaction Information
Submit a claim using the table below.
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must
have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000
km, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps
Inoperative Or Continuously On > Page 11433
the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Disclaimer
Owner Letter
Owner Letter
Dear GM Customer:
As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your
satisfaction with our product is very important to us.
This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado
and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch
could cause the loss of brake lamps or continuous illumination of the brake lamps. The
performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it
may become inoperative.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the brake
lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon
vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles
(160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis
or repair for conditions other than the condition described above is not covered under this special
coverage program.
What You Should Do: Repairs and adjustments qualifying under this special coverage must be
performed by a General Motors dealer. If you believe your vehicle has the condition described
above, you may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by December 31, 2011. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
General Motors Corporation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps
Inoperative Or Continuously On > Page 11434
Enclosure
09186
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Light Switch: > NHTSA09V310000 > Jul > 09 > Recall 09V310000:
Brake Lamp Switch Defect
Brake Light Switch: All Technical Service Bulletins Recall 09V310000: Brake Lamp Switch Defect
VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2009 GMC/Canyon
2004-2009 Isuzu/I-280 2006 Isuzu/I-290 2007-2008 Isuzu/I-350 2006 Isuzu/I-370 2007-2008
MANUFACTURER: General Motors Corp.
MFR'S REPORT DATE: July 28, 2009
NHTSA CAMPAIGN ID NUMBER: 09V310000
NHTSA ACTION NUMBER: RQ09001 COMPONENT: Exterior Lighting: Brake Lights: Switch
POTENTIAL NUMBER OF UNITS AFFECTED: 185903
SUMMARY: GM is recalling 185,903 model year 2004-2009 Chevrolet Colorado, Model year
2004-2009 GMC Canyon, model year 2006 Isuzu I-280, I-350, model year 2007-2008 Isuzu I-290,
and I-370, passenger vehicles originally sold in or currently registered in the states of Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch.
CONSEQUENCE: This condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash.
REMEDY: Dealers will inspect and replace the necessary components as specified in the recall
bulletin free of charge. GM anticipates that parts will be available by February 2010. A special
coverage for vehicles registered in all other states will be implemented in the same time frame. In
the interim, owners who experience the failure can obtain a free repair, however they will be
required to return when the new design part becomes available. Owners may contact Chevrolet at
1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or at
www.gmownercenter.com.
NOTES: GM recall No. 09049. Owners may also contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Page 11439
Brake Light Switch: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Page 11440
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Page 11441
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Page 11442
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Page 11443
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Page 11444
Brake Light Switch: Diagrams
Component Connector End Views
Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Page 11445
Brake Light Switch: Adjustments
Stop Lamp Switch Adjustment
1. Rotate the switch counterclockwise, allowing the retainer to release. 2. Pull the brake pedal
rearward to full stop.
Important: Do not move the brake pedal during switch adjustment as this will cause an
over-adjusted switch which could cause brake drag.
3. While holding the brake pedal FIRMLY in position rearward, push the switch inward fully until the
switch body contacts the brake pedal arm
striker plate. At this point the plunger in the switch should be pushed in.
4. Rotate the switch clockwise until a "click" is heard. 5. The switch is properly adjusted when there
is 7 mm (0.028 in) clearance between the end of the switch barrel and the striker plate on the brake
pedal arm.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Page 11446
Brake Light Switch: Service and Repair
Stop Lamp Switch Replacement
Removal Procedure
1. Disconnect the stop lamp switch electrical connectors (1).
2. Rotate the switch counterclockwise. 3. Remove the switch from the bracket. 4. Remove the
switch from the vehicle.
Installation Procedure
1. Position the switch near the bracket. 2. Ensure the switch key-way is properly indexed to the
plastic retainer. 3. Install and adjust the switch. Refer to Stop Lamp Switch Adjustment (See:
Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service
Bulletins > Page 11447
4. Connect the stop lamp switch electrical connectors (1). 5. Check the switch for proper operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams
Cargo Lamp: Diagrams
Component Connector End Views
Cargo Lamp - Left
Cargo Lamp - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb >
Component Information > Service and Repair
Center Mounted Brake Lamp Bulb: Service and Repair
High Mount Stop Lamp Bulb Replacement
Removal Procedure
1. Remove the screws that retain the center high-mounted stop lamp (CHMSL) lens to the vehicle.
2. Remove the CHMSL from the vehicle.
3. Twist the lamp sockets (1) counterclockwise to remove. 4. Remove the bulbs from the sockets.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb >
Component Information > Service and Repair > Page 11455
1. Install the CHMSL bulbs (1).
2. Install the CHMSL assembly to the vehicle. Ensure that the CHMSL gasket is seated properly.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the screws that retain the CHMSL lens to the vehicle.
Tighten the screws to 2.5 Nm (22 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams
Courtesy Lamp: Diagrams
Component Connector End Views
I/P Courtesy Lamp - Left
I/P Courtesy Lamp - Right
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Page 11459
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Harness
Routing Views
Dimmer Switch: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Harness
Routing Views > Page 11464
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Harness
Routing Views > Page 11465
Dimmer Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 11466
Dimmer Switch: Diagrams
Component Connector End Views
Headlamp and Panel Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams
Dome Lamp: Diagrams
Component Connector End Views
Dome Lamp
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 11470
Dome Lamp: Service and Repair
Dome Lamp Replacement
Removal Procedure
1. Remove the lens from the dome lamp.
2. Carefully use a flat-bladed tool, and release the tabs (2) retaining to the dome lamp to the
headliner. 3. Lower the dome lamp and disconnect the electrical connector (1). 4. Remove the
dome lamp from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 11471
1. Position the dome lamp to the headliner and connect the electrical connector (1). 2. Ensure the
retaining tabs (2) are in the open position. 3. Install the dome lamp into the headliner opening and
close the retaining tabs (2). 4. Ensure the dome lamp is secure to the headliner.
5. Install the lens to the dome lamp.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing
Views
Door Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing
Views > Page 11476
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing
Views > Page 11477
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Left Rear Door Harness Routing (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing
Views > Page 11478
1 - Speaker - Left Rear Door 2 - X312 (Body Harness to Left Rear Door Harness) 3 - X316 (Body
Harness to Left Rear Door Harness) 4 - Seat Belt Pretensioner - Left Front 5 - Door Jamb Switch Driver
Right Rear Door Harness Routing (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing
Views > Page 11479
1 - Speaker - Right Rear Door 2 - Door Jamb Switch - Front Passenger 3 - Seat Belt Pretensioner Right Front 4 - X317 (Body Harness to Right Rear Door Harness) 5 - X311 (Body Harness to Right
Rear Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing
Views > Page 11480
Door Switch: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Left B-Pillar Components (Regular Cab)
1 - Door Jamb Switch - Driver
Left B-Pillar and C-Pillar Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing
Views > Page 11481
1 - Door Jamb Switch - Left Rear 2 - Door Jamb Switch - Driver
Right B-Pillar Components (Regular Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing
Views > Page 11482
1 - Door Jamb Switch - Passenger
Right B-Pillar and C-Pillar Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing
Views > Page 11483
1 - Door Jamb Switch - Right Rear 2 - Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing
Views > Page 11484
Door Switch: Locations Door Component Views
Door Component Views
Left Rear Door Frame Components (Extended Cab)
1 - Door Jamb Switch - Driver
Right Rear Door Frame Components (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing
Views > Page 11485
1 - Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 11486
Door Switch: Diagrams
Component Connector End Views
Door Jamb Switch - Driver
Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 11487
Door Jamb Switch - Left Rear (Crew Cab)
Door Jamb Switch - Right Rear (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 11488
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 11489
Door Switch: Service and Repair
Door Jamb Switch Replacement
Removal Procedure
1. Open the door. 2. Remove the screw retaining the door jamb switch (1) to the body. 3. Remove
the door jamb switch (1) from the body. 4. Disconnect the electrical connector from the switch.
Installation Procedure
1. Connect the electrical connector to the door jamb switch (1). 2. Install the door jamb switch (1) to
the body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 11490
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the screw retaining the door jam switch to the body.
Tighten the door jamb switch screw to 1.5 Nm (13 lb in).
4. Close the door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information
> Service and Repair
Fog/Driving Lamp Bulb: Service and Repair
Front Fog Lamp Bulb Replacement (Colorado)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component
Information > Locations
Fog/Driving Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations > Harness Routing Views
Hazard Warning Switch: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations > Harness Routing Views > Page 11503
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations > Harness Routing Views > Page 11504
Hazard Warning Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations > Page 11505
Hazard Warning Switch: Diagrams
Component Connector End Views
Hazard Warning Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations > Page 11506
Hazard Warning Switch: Service and Repair
Hazard Warning Switch Replacement
Removal Procedure
1. Remove the instrument panel (I/P) accessory trim plate. Refer to Instrument Panel Accessory
Trim Plate Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair).
2. Disconnect the hazard switch electrical connector.
Important: Ensure the tabs retaining the switch to the trim plate are released from the back side of
the trim panel.
3. Release the tabs retaining the switch to the trim plate.
4. Remove the switch (1) from the trim plate.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations > Page 11507
Installation Procedure
1. Position the switch (1) to the trim plate. 2. Ensure the switch key-way is indexed to the trim plate.
3. Install the switch to the trim plate ensuring the tabs are fully seated.
4. Connect the hazard switch electrical connector. 5. Install the I/P accessory trim plate. Refer to
Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair
Headlamp Bulb: Service and Repair
Headlamp Bulb Replacement
Removal Procedure
Warning
Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter
into flying glass fragments. To help avoid personal injury:
* Turn off the lamp switch and allow the bulb to cool before changing the bulb.
* Leave the lamp switch OFF until the bulb change is complete.
* Always wear eye protection when changing a halogen bulb.
* Handle the bulb only by its base. Avoid touching the glass.
* Keep dirt and moisture off the bulb.
* Properly dispose of the used bulb.
* Keep halogen bulbs out of the reach of children.
Caution: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from
your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If
either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe
the bulb dry.
1. Ensure that the headlamp switch is in the OFF position. 2. Ensure that the ignition switch is in
the LOCK position. 3. Remove the front grille. Refer to Grille Replacement (See: Body and
Frame/Grille/Service and Repair). 4. Remove the bolts that retain the headlamp.
5. Push and rotate the high beam headlamp (2), low beam headlamp (3) 1/4 turn counterclockwise
in order to remove the bulb, if needed. 6. Disconnect the electrical connector.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair > Page 11512
1. Connect the electrical connector to the bulb. 2. Push in and rotate the high beam headlamp (2),
low beam headlamp (3) 1/4 turn clockwise in order to install the bulb.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the bolts that retain the headlamp.
Tighten the bolts to 10 Nm (89 lb in).
4. Inspect the headlamps for proper operation. 5. Install the front grille. Refer to Grille Replacement
(See: Body and Frame/Grille/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical
Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention
Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage
Prevention
INFORMATION
Bulletin No.: 02-08-42-001D
Date: June 21, 2010
Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior
Polycarbonate Headlamp Lenses
Models:
2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years and to revise the warning statements.
Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories).
The bulletin is being issued to make dealers and customers aware of chemical damage that may
be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types
of headlamp lenses. This material is used because of its temperature and high impact resistance.
A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are
very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when
treating a vehicle with any type of chemical, such as those recommended for rail dust removal.
Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash
soaps in too high a concentration may also attribute to this condition. This could result in the need
to replace the entire headlamp housing.
Warning
Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and
lenses.
Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over
the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are
on. This action restricts the amount of heat dissipated by the headlamps.
Warning
Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is
being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause
excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens
can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it
could cause the lens to deform. This damage can also be caused by aftermarket shields that are
often tinted in color.
Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins.
This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks.
In more extreme cases, it will begin to melt the lens of the headlamp.
Notice
Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are
not covered under the new vehicle warranty.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations
Headlamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
> Instrument Panel/Center Console Component Views
Headlamp Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
> Instrument Panel/Center Console Component Views > Page 11524
Headlamp Switch: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
> Instrument Panel/Center Console Component Views > Page 11525
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
> Page 11526
Headlamp Switch: Diagrams
Component Connector End Views
Headlamp and Panel Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
> Page 11527
Headlamp Switch: Service and Repair
Headlamp Switch Replacement
Removal Procedure
1. Remove the knee bolster trim panel. Refer to Driver Knee Bolster Panel Replacement (See:
Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
2. Remove the screw retaining the switch to the instrument panel (I/P). 3. Partially remove the
switch from the I/P. 4. Disconnect the switch electrical connector. 5. Remove the switch from the
vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
> Page 11528
1. Position the switch to the I/P. 2. Connect the electrical connector to the switch. 3. Install the
switch to the I/P.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the screw retaining the switch to the I/P.
Tighten the screw to 2.5 Nm (22 lb in).
5. Install the knee bolster trim panel. Refer to Driver Knee Bolster Panel Replacement (See: Body
and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations
High Beam Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Locations
Low Beam Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations
Horn Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams
Horn Switch: Diagrams
Component Connector End Views
Horn Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams > Page
11542
Horn Switch: Service and Repair
Steering Wheel Horn Switch Replacement
Removal Procedure
Warning: Refer to Servicing the SIR System Warning (See: Restraint Systems/Service
Precautions/Servicing the SIR System Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
2. Remove the Inflatable Restraint Steering Wheel module. Refer to Steering Wheel Inflatable
Restraint Module Replacement (See: Restraint
Systems/Air Bag Systems/Air Bag/Service and Repair).
3. Remove the horn plunger from the steering column by pressing inward to the stop and by
rotating the plunger 90 degrees.
4. Disconnect the screws (1, 4) from the steering wheel (3). 5. Remove the horn switch (2) from the
steering wheel (3).
Installation Procedure
1. Install the horn switch (2) to the steering wheel (3).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Connect the screws (1, 4) that secure the contact plate to the steering wheel (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams > Page
11543
Tighten the screws to 5.5 Nm (49 lb in).
3. Install the horn plunger to the steering column. 4. Install the inflator module. Refer to Steering
Wheel Inflatable Restraint Module Replacement (See: Restraint Systems/Air Bag Systems/Air
Bag/Service and Repair).
5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information >
Service and Repair
License Plate Bulb: Service and Repair
License Lamp Bulb Replacement
Removal Procedure
1. Ensure the headlamp switch is in the OFF position. 2. Disconnect the electrical connector (2)
from the license lamp assembly (1). 3. Remove the nut (3) retaining the license lamp to the
bumper. 4. Remove the license lamp assembly from the bumper. 5. Twist the lamp socket
counterclockwise to remove. 6. Remove the bulb.
Installation Procedure
1. Install the bulb to the lamp socket.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information >
Service and Repair > Page 11548
2. Twist the lamp socket clockwise to install. 3. Install the lamp assembly (1) into the bumper.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the license lamp nut (3).
Tighten the nut to 2.5 Nm (22 lb in).
5. Install the electrical connector (2). 6. Inspect the lamp operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information >
Service and Repair
Marker Lamp Bulb: Service and Repair
Park/Turn Signal/Side Marker Lamp Bulb Replacement
Removal Procedure
Warning
Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter
into flying glass fragments. To help avoid personal injury:
* Turn off the lamp switch and allow the bulb to cool before changing the bulb.
* Leave the lamp switch OFF until the bulb change is complete.
* Always wear eye protection when changing a halogen bulb.
* Handle the bulb only by its base. Avoid touching the glass.
* Keep dirt and moisture off the bulb.
* Properly dispose of the used bulb.
* Keep halogen bulbs out of the reach of children.
Caution: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from
your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If
either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe
the bulb dry.
1. Ensure that the headlamp switch is in the OFF position. 2. Ensure that the ignition switch is in
the LOCK position.
3. Open the hood. 4. Release the locking tab (1) on the park, turn, daytime running lamp assembly
by using a flat-bladed tool and pushing the tab on the lamp outward
toward the fender.
5. Rotate the outward edge of the lamp assembly forward. 6. Release the park/turn signal lamp
socket (2) by rotating the socket a quarter turn counter-clockwise. 7. Remove the park, turn signal
lamp bulb (3). 8. Repeat steps 6 and 7 for the daytime running lamp socket (4) and bulb (5).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information >
Service and Repair > Page 11553
1. Secure the bulbs (3,5) into the bulb sockets (2,4) and to the lamp assembly. 2. Insert the inside
edge of the lamp tabs to the grille support. 3. Rotate the lamp assembly into the fender bracket. 4.
Push on the outboard edge of the lamp until an audible click is heard, when the lamp assembly is
secure to the fender. 5. Inspect the lamps for proper operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information >
Locations
Parking Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information >
Service and Repair
Parking Light Bulb: Service and Repair
Park/Turn Signal/Side Marker Lamp Bulb Replacement
Removal Procedure
Warning
Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter
into flying glass fragments. To help avoid personal injury:
* Turn off the lamp switch and allow the bulb to cool before changing the bulb.
* Leave the lamp switch OFF until the bulb change is complete.
* Always wear eye protection when changing a halogen bulb.
* Handle the bulb only by its base. Avoid touching the glass.
* Keep dirt and moisture off the bulb.
* Properly dispose of the used bulb.
* Keep halogen bulbs out of the reach of children.
Caution: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from
your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If
either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe
the bulb dry.
1. Ensure that the headlamp switch is in the OFF position. 2. Ensure that the ignition switch is in
the LOCK position.
3. Open the hood. 4. Release the locking tab (1) on the park, turn, daytime running lamp assembly
by using a flat-bladed tool and pushing the tab on the lamp outward
toward the fender.
5. Rotate the outward edge of the lamp assembly forward. 6. Release the park/turn signal lamp
socket (2) by rotating the socket a quarter turn counter-clockwise. 7. Remove the park, turn signal
lamp bulb (3). 8. Repeat steps 6 and 7 for the daytime running lamp socket (4) and bulb (5).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information >
Service and Repair > Page 11561
1. Secure the bulbs (3,5) into the bulb sockets (2,4) and to the lamp assembly. 2. Insert the inside
edge of the lamp tabs to the grille support. 3. Rotate the lamp assembly into the fender bracket. 4.
Push on the outboard edge of the lamp until an audible click is heard, when the lamp assembly is
secure to the fender. 5. Inspect the lamps for proper operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Fog/Driving Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations
Headlamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations
High Beam Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Horn Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay >
Component Information > Locations
Low Beam Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Parking Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module >
Component Information > Service and Repair
Trailer Lighting Module: Service and Repair
Trailer Lamp Control Module Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Instrument Panel/Center Console Component Views
Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Instrument Panel/Center Console Component Views > Page 11589
Ambient Light Sensor: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Instrument Panel/Center Console Component Views > Page 11590
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 11591
Ambient Light Sensor: Diagrams
Component Connector End Views
Ambient Light Sensor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 11592
Ambient Light Sensor: Service and Repair
Ambient Light Sensor Replacement
Removal Procedure
1. Carefully use a flat-bladed tool, and remove the sensor from the upper portion of the instrument
panel (I/P).
2. Disconnect the electrical connector (2) from the sensor ensuring the connector does NOT fall
through the hole in the I/P. 3. Remove the sensor from the vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 11593
1. Connect the electrical connector (2) to the sensor.
2. Align the sensor to the I/P for installation. 3. Apply downward pressure to the sensor head in
order to seat the sensor to the I/P.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations
Backup Lamp Switch: Locations
Powertrain Component Views
Right Side of the Transmission Components (MA5)
1 - Backup Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 11597
Backup Lamp Switch: Diagrams
Component Connector End Views
Backup Lamp Switch (MA5)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 11598
Backup Lamp Switch: Service and Repair
Backup Lamp Switch Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance/Vehicle Lifting/Service and Repair).
2. Disconnect the backup lamp switch electrical connector (1) at the pigtail. 3. Open the tie strap
securing the pigtail to the transmission.
4. Remove the backup lamp switch with the aluminum washer.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 11599
Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle
Damage Warnings/Component Fastener Tightening Caution).
1. Install the backup lamp switch with a NEW aluminum washer into the transmission case.
Tighten the backup lamp switch to 44 Nm (32 lb ft).
2. Secure the pigtail to the transmission with the tie strap. 3. Connect the backup lamp switch
electrical connector (1) at the pigtail. 4. Lower the vehicle.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON
Technical Service Bulletin # 09049A Date: 110314
Recall - Brake Lamps Inoperative/Continuously ON
SAFETY
Bulletin No.: 09049A
Date: March 14, 2011
Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination
Models:
2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida,
Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas,
U.S. Virgin Islands, Utah
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s). Please discard all copies of bulletin 09049, issued July 2010.
Condition
General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch. Performance of the brakes is not
affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could
become inoperative.
Correction
Dealers are to install a new brake lamp switch assembly.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles
registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New
Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these
VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate
Vehicle History link. Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report
available if they have no involved vehicles currently assigned.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 11608
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
Parts required to complete this recall are to be obtained from General Motors Customer Care and
Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal
orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts
should be ordered on a CSO = Customer Special Order.
Service Procedure
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Customer Reimbursement - For GM US
All customer requests for reimbursement of previously paid repairs for the recall condition will be
handled by the Customer Assistance Center, not by dealers.
Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section
6.1.12, for specific procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs for the recall condition are to be
submitted to the dealer by August 31, 2011.
All reasonable customer paid receipts should be considered for reimbursement. The amount to be
reimbursed will be limited to the amount the repair would have cost if completed by an authorized
General Motors dealer.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a
description of the repair, and the person or entity performing the repair.
Claims for customer reimbursement on previously paid repairs are to be submitted as required by
WINS.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement verification.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 11609
* The amount identified in the "Net Item" column should represent the dollar amount reimbursed to
the customer.
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
included with this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the attached sample letter.
Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions)
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a
recall of this type must be adequately repaired within a reasonable time after the customer has
tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not adequately repaired
within a reasonable time, the customer may be entitled to an identical or reasonably equivalent
vehicle at no charge or to a refund of the purchase price less a reasonable allowance for
depreciation. To avoid having to provide these burdensome remedies, every effort must be made
to promptly schedule an appointment with each customer and to repair their vehicle as soon as
possible. In the recall notification letters, customers are told how to contact the US National
Highway Traffic Safety Administration if the recall is not completed within a reasonable time.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers' possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
Disclaimer
Owner Letter
Owner Letter
(Letter sent to customers in Phase 1 Notification)
Dear General Motors Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 11610
continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as
designed due to contamination in the switch. Performance of the brakes is not affected. However,
this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps
to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions
and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative.
What will we do? When parts are available after August 2, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment on or
after August 2, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the Owner Center at www.gmownercenter.com.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049
Division Owner Letter
Division Owner Letter
(Letter sent to customer in Phase 2 notification)
Dear General Motors Customer:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 11611
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
- Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work
as designed due to contamination in the switch. Performance of the brakes is not affected.
However, this condition could cause the simultaneous loss of all brake lamps or cause all of the
brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could
become inoperative.
What will we do? When parts are available after August 26, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment onor
after August 26, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
GM dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049-2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On
Technical Service Bulletin # 09186B Date: 110314
Campaign - Brake Lamps Inoperative Or Continuously On
SPECIAL COVERAGE
Bulletin No.: 09186B
Date: March 14, 2011
Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR
CONTINUOUS ILLUMINATION
Models:
2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030.
If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010.
Condition
Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may
comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be
caused by contamination in the brake lamp switch. The performance of the brakes is not affected.
Also, if equipped, they may comment about the loss of cruise control.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 7 years or 100,000
miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership.
Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to
the customer.
For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after
September 28, 2010, are covered by this special coverage and must be submitted using the labor
operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010,
must be submitted to the Service Contract provider.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built
within the following VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable
Warranties section in the Global Warranty Management system.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On > Page 11616
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of
these switches on their shelves. Please verify your dealer inventory before ordering additional
quantities.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter shown in this bulletin - actual divisional letter may vary slightly).
Service Procedure
Note
Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the
vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Warranty Transaction Information
Submit a claim using the table below.
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must
have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000
km, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On > Page 11617
the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Disclaimer
Owner Letter
Owner Letter
Dear GM Customer:
As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your
satisfaction with our product is very important to us.
This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado
and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch
could cause the loss of brake lamps or continuous illumination of the brake lamps. The
performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it
may become inoperative.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the brake
lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon
vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles
(160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis
or repair for conditions other than the condition described above is not covered under this special
coverage program.
What You Should Do: Repairs and adjustments qualifying under this special coverage must be
performed by a General Motors dealer. If you believe your vehicle has the condition described
above, you may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by December 31, 2011. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
General Motors Corporation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On > Page 11618
Enclosure
09186
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > NHTSA09V310000 > Jul > 09 >
Recall 09V310000: Brake Lamp Switch Defect
Brake Light Switch: Recalls Recall 09V310000: Brake Lamp Switch Defect
VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2009 GMC/Canyon
2004-2009 Isuzu/I-280 2006 Isuzu/I-290 2007-2008 Isuzu/I-350 2006 Isuzu/I-370 2007-2008
MANUFACTURER: General Motors Corp.
MFR'S REPORT DATE: July 28, 2009
NHTSA CAMPAIGN ID NUMBER: 09V310000
NHTSA ACTION NUMBER: RQ09001 COMPONENT: Exterior Lighting: Brake Lights: Switch
POTENTIAL NUMBER OF UNITS AFFECTED: 185903
SUMMARY: GM is recalling 185,903 model year 2004-2009 Chevrolet Colorado, Model year
2004-2009 GMC Canyon, model year 2006 Isuzu I-280, I-350, model year 2007-2008 Isuzu I-290,
and I-370, passenger vehicles originally sold in or currently registered in the states of Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch.
CONSEQUENCE: This condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash.
REMEDY: Dealers will inspect and replace the necessary components as specified in the recall
bulletin free of charge. GM anticipates that parts will be available by February 2010. A special
coverage for vehicles registered in all other states will be implemented in the same time frame. In
the interim, owners who experience the failure can obtain a free repair, however they will be
required to return when the new design part becomes available. Owners may contact Chevrolet at
1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or at
www.gmownercenter.com.
NOTES: GM recall No. 09049. Owners may also contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A >
Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON
Technical Service Bulletin # 09049A Date: 110314
Recall - Brake Lamps Inoperative/Continuously ON
SAFETY
Bulletin No.: 09049A
Date: March 14, 2011
Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination
Models:
2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida,
Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas,
U.S. Virgin Islands, Utah
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s). Please discard all copies of bulletin 09049, issued July 2010.
Condition
General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch. Performance of the brakes is not
affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could
become inoperative.
Correction
Dealers are to install a new brake lamp switch assembly.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles
registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New
Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these
VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate
Vehicle History link. Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report
available if they have no involved vehicles currently assigned.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A >
Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11628
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
Parts required to complete this recall are to be obtained from General Motors Customer Care and
Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal
orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts
should be ordered on a CSO = Customer Special Order.
Service Procedure
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Customer Reimbursement - For GM US
All customer requests for reimbursement of previously paid repairs for the recall condition will be
handled by the Customer Assistance Center, not by dealers.
Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section
6.1.12, for specific procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs for the recall condition are to be
submitted to the dealer by August 31, 2011.
All reasonable customer paid receipts should be considered for reimbursement. The amount to be
reimbursed will be limited to the amount the repair would have cost if completed by an authorized
General Motors dealer.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a
description of the repair, and the person or entity performing the repair.
Claims for customer reimbursement on previously paid repairs are to be submitted as required by
WINS.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement verification.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A >
Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11629
* The amount identified in the "Net Item" column should represent the dollar amount reimbursed to
the customer.
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
included with this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the attached sample letter.
Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions)
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a
recall of this type must be adequately repaired within a reasonable time after the customer has
tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not adequately repaired
within a reasonable time, the customer may be entitled to an identical or reasonably equivalent
vehicle at no charge or to a refund of the purchase price less a reasonable allowance for
depreciation. To avoid having to provide these burdensome remedies, every effort must be made
to promptly schedule an appointment with each customer and to repair their vehicle as soon as
possible. In the recall notification letters, customers are told how to contact the US National
Highway Traffic Safety Administration if the recall is not completed within a reasonable time.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers' possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
Disclaimer
Owner Letter
Owner Letter
(Letter sent to customers in Phase 1 Notification)
Dear General Motors Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A >
Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11630
continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as
designed due to contamination in the switch. Performance of the brakes is not affected. However,
this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps
to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions
and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative.
What will we do? When parts are available after August 2, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment on or
after August 2, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the Owner Center at www.gmownercenter.com.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049
Division Owner Letter
Division Owner Letter
(Letter sent to customer in Phase 2 notification)
Dear General Motors Customer:
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A >
Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11631
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
General Motors has decided that a defect that relates to motor vehicle safety exists in certain
2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned about
your safety and continued satisfaction with our products.
Important
- Your vehicle is involved in safety recall 09049.
- Schedule an appointment with your GM dealer.
- This service will be performed for you at no charge.
Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work
as designed due to contamination in the switch. Performance of the brakes is not affected.
However, this condition could cause the simultaneous loss of all brake lamps or cause all of the
brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could
become inoperative.
What will we do? When parts are available after August 26, 2010, your GM dealer will install a new
brake lamp switch assembly. This service will be performed for you at no charge.
If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle
service or some other form of courtesy transportation while your vehicle is at the dealership for this
repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation.
What should you do? You should contact your GM dealer to arrange a service appointment onor
after August 26, 2010.
Did you already pay for this repair? The enclosed form explains what reimbursement is available
and how to request reimbursement if you have paid for repairs for the recall condition. Even though
you may have already had this condition corrected, you will still need to take your vehicle to your
GM dealer for additional repairs.
Do you have questions? If you have questions or concerns that your dealer is unable to resolve,
please contact the appropriate Customer Assistance Center at the number listed below. More
information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you may
wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey
Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236
(TTY 1.800.424.9153), or go to http://www.safercar.gov.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy
of this notice to the lessee within ten days.
Scott Lawson
Director,
Customer and Relationship Services
Enclosure
09049-2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B >
Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On
Technical Service Bulletin # 09186B Date: 110314
Campaign - Brake Lamps Inoperative Or Continuously On
SPECIAL COVERAGE
Bulletin No.: 09186B
Date: March 14, 2011
Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR
CONTINUOUS ILLUMINATION
Models:
2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON
Supercede: The Part Information, Service Procedure, and Warranty Transaction Information
sections in this bulletin have been revised to include the replacement of burned out brake lamp
bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030.
If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010.
Condition
Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may
comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be
caused by contamination in the brake lamp switch. The performance of the brakes is not affected.
Also, if equipped, they may comment about the loss of cruise control.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 7 years or 100,000
miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership.
Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to
the customer.
For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after
September 28, 2010, are covered by this special coverage and must be submitted using the labor
operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010,
must be submitted to the Service Contract provider.
Vehicles Involved
Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built
within the following VIN breakpoints:
Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable
Warranties section in the Global Warranty Management system.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B >
Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11636
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of
these switches on their shelves. Please verify your dealer inventory before ordering additional
quantities.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter shown in this bulletin - actual divisional letter may vary slightly).
Service Procedure
Note
Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the
vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the
repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety
recall or has already had the safety recall performed, proceed with repairs using this Special
Coverage bulletin.
1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install
a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require
replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb
Replacement in
SI.
Warranty Transaction Information
Submit a claim using the table below.
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must
have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000
km, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B >
Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11637
the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Disclaimer
Owner Letter
Owner Letter
Dear GM Customer:
As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your
satisfaction with our product is very important to us.
This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado
and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch
could cause the loss of brake lamps or continuous illumination of the brake lamps. The
performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it
may become inoperative.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the brake
lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon
vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles
(160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis
or repair for conditions other than the condition described above is not covered under this special
coverage program.
What You Should Do: Repairs and adjustments qualifying under this special coverage must be
performed by a General Motors dealer. If you believe your vehicle has the condition described
above, you may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by December 31, 2011. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
General Motors Corporation
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B >
Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11638
Enclosure
09186
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: >
NHTSA09V310000 > Jul > 09 > Recall 09V310000: Brake Lamp Switch Defect
Brake Light Switch: All Technical Service Bulletins Recall 09V310000: Brake Lamp Switch Defect
VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2009 GMC/Canyon
2004-2009 Isuzu/I-280 2006 Isuzu/I-290 2007-2008 Isuzu/I-350 2006 Isuzu/I-370 2007-2008
MANUFACTURER: General Motors Corp.
MFR'S REPORT DATE: July 28, 2009
NHTSA CAMPAIGN ID NUMBER: 09V310000
NHTSA ACTION NUMBER: RQ09001 COMPONENT: Exterior Lighting: Brake Lights: Switch
POTENTIAL NUMBER OF UNITS AFFECTED: 185903
SUMMARY: GM is recalling 185,903 model year 2004-2009 Chevrolet Colorado, Model year
2004-2009 GMC Canyon, model year 2006 Isuzu I-280, I-350, model year 2007-2008 Isuzu I-290,
and I-370, passenger vehicles originally sold in or currently registered in the states of Alabama,
Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South
Carolina, Texas, U.S. Virgin Islands and Utah. Some of these vehicles have a brake lamp switch
that may not work as designed due to contamination in the switch.
CONSEQUENCE: This condition could cause the simultaneous loss of all brake lamps or cause all
of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the
driver's intentions and could lead to a vehicle crash.
REMEDY: Dealers will inspect and replace the necessary components as specified in the recall
bulletin free of charge. GM anticipates that parts will be available by February 2010. A special
coverage for vehicles registered in all other states will be implemented in the same time frame. In
the interim, owners who experience the failure can obtain a free repair, however they will be
required to return when the new design part becomes available. Owners may contact Chevrolet at
1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or at
www.gmownercenter.com.
NOTES: GM recall No. 09049. Owners may also contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 11643
Brake Light Switch: Locations
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise
Release Switch 18 - Park Brake Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 11644
19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25
- C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310
(Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger
Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Extended Cab)
1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301
4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to
Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 11645
8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted
Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body
Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor
16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp
Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door
Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to
Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch
(MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 11646
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear
Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door
Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left
Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt
Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21
- TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 11647
25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness
to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to
Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof
Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness
to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 11648
Brake Light Switch: Diagrams
Component Connector End Views
Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 11649
Brake Light Switch: Adjustments
Stop Lamp Switch Adjustment
1. Rotate the switch counterclockwise, allowing the retainer to release. 2. Pull the brake pedal
rearward to full stop.
Important: Do not move the brake pedal during switch adjustment as this will cause an
over-adjusted switch which could cause brake drag.
3. While holding the brake pedal FIRMLY in position rearward, push the switch inward fully until the
switch body contacts the brake pedal arm
striker plate. At this point the plunger in the switch should be pushed in.
4. Rotate the switch clockwise until a "click" is heard. 5. The switch is properly adjusted when there
is 7 mm (0.028 in) clearance between the end of the switch barrel and the striker plate on the brake
pedal arm.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 11650
Brake Light Switch: Service and Repair
Stop Lamp Switch Replacement
Removal Procedure
1. Disconnect the stop lamp switch electrical connectors (1).
2. Rotate the switch counterclockwise. 3. Remove the switch from the bracket. 4. Remove the
switch from the vehicle.
Installation Procedure
1. Position the switch near the bracket. 2. Ensure the switch key-way is properly indexed to the
plastic retainer. 3. Install and adjust the switch. Refer to Stop Lamp Switch Adjustment (See:
Adjustments).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 11651
4. Connect the stop lamp switch electrical connectors (1). 5. Check the switch for proper operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Locations
Combination Switch: Locations
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views
Door Switch: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 2 of 3 (Regular Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7
- X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module
11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left
Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 11659
17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to
Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body
Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail
Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to
Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror
Body Harness Routing 2 of 3 (Crew Cab)
1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 11660
6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High
Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat
Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body
Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park
Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body
Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver
Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering
Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position
(APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body
Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside
Rearview Mirror
Left Rear Door Harness Routing (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 11661
1 - Speaker - Left Rear Door 2 - X312 (Body Harness to Left Rear Door Harness) 3 - X316 (Body
Harness to Left Rear Door Harness) 4 - Seat Belt Pretensioner - Left Front 5 - Door Jamb Switch Driver
Right Rear Door Harness Routing (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 11662
1 - Speaker - Right Rear Door 2 - Door Jamb Switch - Front Passenger 3 - Seat Belt Pretensioner Right Front 4 - X317 (Body Harness to Right Rear Door Harness) 5 - X311 (Body Harness to Right
Rear Door Harness)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 11663
Door Switch: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Left B-Pillar Components (Regular Cab)
1 - Door Jamb Switch - Driver
Left B-Pillar and C-Pillar Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 11664
1 - Door Jamb Switch - Left Rear 2 - Door Jamb Switch - Driver
Right B-Pillar Components (Regular Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 11665
1 - Door Jamb Switch - Passenger
Right B-Pillar and C-Pillar Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 11666
1 - Door Jamb Switch - Right Rear 2 - Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 11667
Door Switch: Locations Door Component Views
Door Component Views
Left Rear Door Frame Components (Extended Cab)
1 - Door Jamb Switch - Driver
Right Rear Door Frame Components (Extended Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Harness Routing Views > Page 11668
1 - Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Page 11669
Door Switch: Diagrams
Component Connector End Views
Door Jamb Switch - Driver
Door Jamb Switch - Passenger
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Page 11670
Door Jamb Switch - Left Rear (Crew Cab)
Door Jamb Switch - Right Rear (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Page 11671
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Page 11672
Door Switch: Service and Repair
Door Jamb Switch Replacement
Removal Procedure
1. Open the door. 2. Remove the screw retaining the door jamb switch (1) to the body. 3. Remove
the door jamb switch (1) from the body. 4. Disconnect the electrical connector from the switch.
Installation Procedure
1. Connect the electrical connector to the door jamb switch (1). 2. Install the door jamb switch (1) to
the body.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Page 11673
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the screw retaining the door jam switch to the body.
Tighten the door jamb switch screw to 1.5 Nm (13 lb in).
4. Close the door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Locations > Harness Routing Views
Hazard Warning Switch: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Locations > Harness Routing Views > Page 11678
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Locations > Harness Routing Views > Page 11679
Hazard Warning Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Locations > Page 11680
Hazard Warning Switch: Diagrams
Component Connector End Views
Hazard Warning Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Locations > Page 11681
Hazard Warning Switch: Service and Repair
Hazard Warning Switch Replacement
Removal Procedure
1. Remove the instrument panel (I/P) accessory trim plate. Refer to Instrument Panel Accessory
Trim Plate Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair).
2. Disconnect the hazard switch electrical connector.
Important: Ensure the tabs retaining the switch to the trim plate are released from the back side of
the trim panel.
3. Release the tabs retaining the switch to the trim plate.
4. Remove the switch (1) from the trim plate.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Locations > Page 11682
Installation Procedure
1. Position the switch (1) to the trim plate. 2. Ensure the switch key-way is indexed to the trim plate.
3. Install the switch to the trim plate ensuring the tabs are fully seated.
4. Connect the hazard switch electrical connector. 5. Install the I/P accessory trim plate. Refer to
Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Instrument Panel/Center Console Component Views
Headlamp Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Instrument Panel/Center Console Component Views > Page 11687
Headlamp Switch: Locations Harness Routing Views
Harness Routing Views
I/P Harness Routing
1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver
(U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication
Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM)
X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power
Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell
Left 16 - Data Link Connector (DLC)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Instrument Panel/Center Console Component Views > Page 11688
17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument
Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 11689
Headlamp Switch: Diagrams
Component Connector End Views
Headlamp and Panel Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 11690
Headlamp Switch: Service and Repair
Headlamp Switch Replacement
Removal Procedure
1. Remove the knee bolster trim panel. Refer to Driver Knee Bolster Panel Replacement (See:
Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair).
2. Remove the screw retaining the switch to the instrument panel (I/P). 3. Partially remove the
switch from the I/P. 4. Disconnect the switch electrical connector. 5. Remove the switch from the
vehicle.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 11691
1. Position the switch to the I/P. 2. Connect the electrical connector to the switch. 3. Install the
switch to the I/P.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the screw retaining the switch to the I/P.
Tighten the screw to 2.5 Nm (22 lb in).
5. Install the knee bolster trim panel. Refer to Driver Knee Bolster Panel Replacement (See: Body
and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Diagrams
Horn Switch: Diagrams
Component Connector End Views
Horn Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Diagrams > Page 11695
Horn Switch: Service and Repair
Steering Wheel Horn Switch Replacement
Removal Procedure
Warning: Refer to Servicing the SIR System Warning (See: Restraint Systems/Service
Precautions/Servicing the SIR System Warning).
1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
2. Remove the Inflatable Restraint Steering Wheel module. Refer to Steering Wheel Inflatable
Restraint Module Replacement (See: Restraint
Systems/Air Bag Systems/Air Bag/Service and Repair).
3. Remove the horn plunger from the steering column by pressing inward to the stop and by
rotating the plunger 90 degrees.
4. Disconnect the screws (1, 4) from the steering wheel (3). 5. Remove the horn switch (2) from the
steering wheel (3).
Installation Procedure
1. Install the horn switch (2) to the steering wheel (3).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Connect the screws (1, 4) that secure the contact plate to the steering wheel (3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Diagrams > Page 11696
Tighten the screws to 5.5 Nm (49 lb in).
3. Install the horn plunger to the steering column. 4. Install the inflator module. Refer to Steering
Wheel Inflatable Restraint Module Replacement (See: Restraint Systems/Air Bag Systems/Air
Bag/Service and Repair).
5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
Turn Signal Switch: Locations
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement
Turn Signal Switch: Service and Repair Multifunction Turn Signal Switch Housing Replacement
Multifunction Turn Signal Switch Housing Replacement
Removal Procedure
1. Remove the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch
Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch
Replacement).
2. Remove the multifunction turn signal switch housing bolts. 3. Remove the multifunction turn
signal switch housing.
Installation Procedure
1. Install the multifunction turn signal switch housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the multifunction turn signal switch housing bolts.
Tighten the bolts to 2.5 Nm (22 lb in).
3. Install the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch
Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 11702
Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement
Turn Signal Multifunction Switch Replacement
Removal Procedure
Note: The turn signal multifunction switch and Inflatable restraint steering wheel module coil are
serviced as an assembly.
1. Remove the steering wheel. Refer to Steering Wheel Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and
Repair/Steering Wheel Replacement).
2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
3. Disconnect any electrical connectors and remove the wiring harness from any retainers as
needed.
4. Remove the turn signal multifunction switch bolts. 5. Slide the multifunction turn signal switch off
of the steering column.
Installation Procedure
Note: A new multifunction turn signal switch will come precentered with a centering tab attached.
Do NOT remove the centering tab until installation is complete. Failure to follow procedure will
cause a misalignment of the multifunction turn signal switch and centering will be required.
If reusing the existing multifunction turn signal switch, you must center it. Refer to Inflatable
Restraint Steering Wheel Module Coil Centering ( See: Restraint Systems/Air Bag
Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Procedures).
1. Slide the multifunction turn signal switch onto the steering column.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 11703
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the multifunction turn signal switch bolts.
Tighten the bolts to 7 Nm (62 lb in).
3. Route the wire harness assembly down the steering column.
4. Connect any electrical connectors and install the wiring harness through any retainers as
needed. 5. Remove the centering tab from the multifunction turn signal switch. 6. Install the
steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering
and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
7. Install the steering wheel. Refer to Steering Wheel Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and
Repair/Steering Wheel Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and
Repair
Tail Light Bulb: Service and Repair
Tail Lamp Bulb Replacement
Removal Procedure
1. Open the tailgate. 2. Remove the screws (1) from the tail lamp assembly. 3. Remove the lamp
assembly.
4. Remove the tail lamp sockets by depressing the locking tab and rotating counterclockwise. 5.
Remove the bulbs from the tail lamp and/or side marker lamp sockets.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and
Repair > Page 11708
1. Install the bulbs to the tail lamp, and/or side marker lamp sockets. 2. Install the tail lamp sockets
to the tail lamp, rotating clockwise until the locking tab is fully seated.
3. Press the tail lamp to the rear body panel until fully seated.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the tail lamp screws (1) to the tail lamp.
Tighten the tail lamp screws (1) to 3 Nm (26 lb in).
5. Close the tailgate.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Service and
Repair
Trailer Lighting Module: Service and Repair
Trailer Lamp Control Module Replacement
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Locations
Combination Switch: Locations
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component
Information > Service and Repair
Turn Signal Bulb: Service and Repair
Park/Turn Signal/Side Marker Lamp Bulb Replacement
Removal Procedure
Warning
Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter
into flying glass fragments. To help avoid personal injury:
* Turn off the lamp switch and allow the bulb to cool before changing the bulb.
* Leave the lamp switch OFF until the bulb change is complete.
* Always wear eye protection when changing a halogen bulb.
* Handle the bulb only by its base. Avoid touching the glass.
* Keep dirt and moisture off the bulb.
* Properly dispose of the used bulb.
* Keep halogen bulbs out of the reach of children.
Caution: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from
your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If
either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe
the bulb dry.
1. Ensure that the headlamp switch is in the OFF position. 2. Ensure that the ignition switch is in
the LOCK position.
3. Open the hood. 4. Release the locking tab (1) on the park, turn, daytime running lamp assembly
by using a flat-bladed tool and pushing the tab on the lamp outward
toward the fender.
5. Rotate the outward edge of the lamp assembly forward. 6. Release the park/turn signal lamp
socket (2) by rotating the socket a quarter turn counter-clockwise. 7. Remove the park, turn signal
lamp bulb (3). 8. Repeat steps 6 and 7 for the daytime running lamp socket (4) and bulb (5).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component
Information > Service and Repair > Page 11720
1. Secure the bulbs (3,5) into the bulb sockets (2,4) and to the lamp assembly. 2. Insert the inside
edge of the lamp tabs to the grille support. 3. Rotate the lamp assembly into the fender bracket. 4.
Push on the outboard edge of the lamp until an audible click is heard, when the lamp assembly is
secure to the fender. 5. Inspect the lamps for proper operation.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information >
Locations
Turn Signal Switch: Locations
Instrument Panel/Center Console Component Views
Front of the I/P Components
1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch
4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio
8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control
Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information >
Service and Repair > Multifunction Turn Signal Switch Housing Replacement
Turn Signal Switch: Service and Repair Multifunction Turn Signal Switch Housing Replacement
Multifunction Turn Signal Switch Housing Replacement
Removal Procedure
1. Remove the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch
Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch
Replacement).
2. Remove the multifunction turn signal switch housing bolts. 3. Remove the multifunction turn
signal switch housing.
Installation Procedure
1. Install the multifunction turn signal switch housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the multifunction turn signal switch housing bolts.
Tighten the bolts to 2.5 Nm (22 lb in).
3. Install the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch
Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information >
Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 11726
Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement
Turn Signal Multifunction Switch Replacement
Removal Procedure
Note: The turn signal multifunction switch and Inflatable restraint steering wheel module coil are
serviced as an assembly.
1. Remove the steering wheel. Refer to Steering Wheel Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and
Repair/Steering Wheel Replacement).
2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
3. Disconnect any electrical connectors and remove the wiring harness from any retainers as
needed.
4. Remove the turn signal multifunction switch bolts. 5. Slide the multifunction turn signal switch off
of the steering column.
Installation Procedure
Note: A new multifunction turn signal switch will come precentered with a centering tab attached.
Do NOT remove the centering tab until installation is complete. Failure to follow procedure will
cause a misalignment of the multifunction turn signal switch and centering will be required.
If reusing the existing multifunction turn signal switch, you must center it. Refer to Inflatable
Restraint Steering Wheel Module Coil Centering ( See: Restraint Systems/Air Bag
Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Procedures).
1. Slide the multifunction turn signal switch onto the steering column.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information >
Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 11727
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the multifunction turn signal switch bolts.
Tighten the bolts to 7 Nm (62 lb in).
3. Route the wire harness assembly down the steering column.
4. Connect any electrical connectors and install the wiring harness through any retainers as
needed. 5. Remove the centering tab from the multifunction turn signal switch. 6. Install the
steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering
and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Cover Replacement).
7. Install the steering wheel. Refer to Steering Wheel Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and
Repair/Steering Wheel Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information
Heated Glass Element: Customer Interest A/C - Window Defroster Contact/Tab Repair Information
INFORMATION
Bulletin No.: 03-08-48-006H
Date: April 11, 2011
Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab
Models:
2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3
2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear
Window Defroster - RPO C49
Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate
Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories).
Repair Suggestions
Soldering Defroster Contact Tabs
In many cases the terminal tab will still be in the connector when you examine the vehicle. For
Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass),
always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector
(P/N 12034110). For all other vehicles, reconnect the original defroster tab.
In most applications it is preferable to create a new solder connection to reattach a separated rear
defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is
equal to, or stronger than, the original. The generic procedure below is not very time intensive, but
does include minor preparation work to create a good bonding surface. Be sure to follow each of
the steps, as combined they will produce the strongest bond possible. Please consider the
following before attempting the repair:
- Soldering introduces significant heat to the glass window of the vehicle. When performing the
re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and
have the solder in your other hand, ready to go, the moment you have enough heat to melt the
solder.
- If it is winter, bring the vehicle into the service garage and remove any snow from the back
window area. Allow time for the glass to warm to the temperature inside the building. Soldering
creates a "hot spot" in the glass. DO NOT solder on cold glass.
Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass
breakage. ALWAYS wear safety glasses when performing this repair!
- You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with
conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar,
making a strong and lasting repair.
- Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this
repair. Placing a shop towel under the soldering area is sufficient protection.
Soldering Procedure
1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a
new connector to the feed wire. The proper
connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5.
- Insert Delphi pick 12094430 to depress the locking tab on the terminal.
- Insert Delphi pick 12094429 to release the secondary lock tab.
Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with
moveable glass.
2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly
seated connector may cause excessive resistance
and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical
connector tab to the defroster tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 11737
3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size
utility models) and the defroster buss bar with fine
grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder,
but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close
up of a properly prepared surface.
Tip You may want to mask the glass around the contact area with tape. This is easy to do and will
allow you to safely prepare the contact surface without the risk of scratching the glass or the black
painted shading.
Important Most rear glass has a black painted masking around the edge of the glass. When
cleaning up the connection surface, be very careful not to damage the surface of the black shading
or the surface of the glass.
4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to
remove any residual oil or dirt.
Important
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 11738
You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with
conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is
available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for
this repair.
5. For this step, it is permitted that two technicians be used if required. Heat the new connector on
the surface of the buss bar that is to be soldered.
Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep
the solder ready and begin flowing out the solder as soon as the melting temperature has been
reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the
solder around the new contacts base. In this manner, as the melting point of the solder is reached,
a layer is deposited on the bottom side of the contact.
Important Try to align the new contact so that it is positioned with the same orientation as the
original contact.
6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the
performance of the bond; however, while it is unlikely
that customers may refer to the appearance of the rear window defroster and its components as a
positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor
cosmetic application.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Parts Information
Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada,
1-800-563-1717).
Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at
1-800-843-7422.
All other parts can be ordered through GMSPO or SSPO.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 11739
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information
Heated Glass Element: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair
Information
INFORMATION
Bulletin No.: 03-08-48-006H
Date: April 11, 2011
Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab
Models:
2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3
2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear
Window Defroster - RPO C49
Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate
Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories).
Repair Suggestions
Soldering Defroster Contact Tabs
In many cases the terminal tab will still be in the connector when you examine the vehicle. For
Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass),
always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector
(P/N 12034110). For all other vehicles, reconnect the original defroster tab.
In most applications it is preferable to create a new solder connection to reattach a separated rear
defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is
equal to, or stronger than, the original. The generic procedure below is not very time intensive, but
does include minor preparation work to create a good bonding surface. Be sure to follow each of
the steps, as combined they will produce the strongest bond possible. Please consider the
following before attempting the repair:
- Soldering introduces significant heat to the glass window of the vehicle. When performing the
re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and
have the solder in your other hand, ready to go, the moment you have enough heat to melt the
solder.
- If it is winter, bring the vehicle into the service garage and remove any snow from the back
window area. Allow time for the glass to warm to the temperature inside the building. Soldering
creates a "hot spot" in the glass. DO NOT solder on cold glass.
Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass
breakage. ALWAYS wear safety glasses when performing this repair!
- You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with
conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar,
making a strong and lasting repair.
- Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this
repair. Placing a shop towel under the soldering area is sufficient protection.
Soldering Procedure
1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a
new connector to the feed wire. The proper
connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5.
- Insert Delphi pick 12094430 to depress the locking tab on the terminal.
- Insert Delphi pick 12094429 to release the secondary lock tab.
Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with
moveable glass.
2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly
seated connector may cause excessive resistance
and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical
connector tab to the defroster tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 11745
3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size
utility models) and the defroster buss bar with fine
grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder,
but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close
up of a properly prepared surface.
Tip You may want to mask the glass around the contact area with tape. This is easy to do and will
allow you to safely prepare the contact surface without the risk of scratching the glass or the black
painted shading.
Important Most rear glass has a black painted masking around the edge of the glass. When
cleaning up the connection surface, be very careful not to damage the surface of the black shading
or the surface of the glass.
4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to
remove any residual oil or dirt.
Important
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 11746
You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with
conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is
available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for
this repair.
5. For this step, it is permitted that two technicians be used if required. Heat the new connector on
the surface of the buss bar that is to be soldered.
Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep
the solder ready and begin flowing out the solder as soon as the melting temperature has been
reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the
solder around the new contacts base. In this manner, as the melting point of the solder is reached,
a layer is deposited on the bottom side of the contact.
Important Try to align the new contact so that it is positioned with the same orientation as the
original contact.
6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the
performance of the bond; however, while it is unlikely
that customers may refer to the appearance of the rear window defroster and its components as a
positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor
cosmetic application.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Parts Information
Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada,
1-800-563-1717).
Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at
1-800-843-7422.
All other parts can be ordered through GMSPO or SSPO.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 11747
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Harness Routing Views
Power Window Switch: Locations Harness Routing Views
Harness Routing Views
Driver Door Harness Routing
1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside
Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body
Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver
Front Passenger Door Harness Routing
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Harness Routing Views > Page 11753
1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front
Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body
Harness) 9 - X210 (Body Harness to Front Passenger Door Harness)
Right Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Harness Routing Views > Page 11754
1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock
Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door
Harness)
Left Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Harness Routing Views > Page 11755
1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness
to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Harness Routing Views > Page 11756
Power Window Switch: Locations Door Component Views
Door Component Views
Driver Door Components
1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker
- Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch
(DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF)
Front Passenger Door Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Harness Routing Views > Page 11757
1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door
Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210
Left Rear Door Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Harness Routing Views > Page 11758
1 - Speaker - Left Rear 2 - Window Switch - Left Rear (A31) 3 - X316 4 - Window Motor - Left Rear
(A31) 5 - Door Lock Actuator - Left Rear (AU3)
Right Rear Door Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Harness Routing Views > Page 11759
1 - Window Switch - Right Rear (A31) 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right
Rear (AU3) 4 - Window Motor - Right Rear (A31) 5 - X317
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Page 11760
Power Window Switch: Diagrams
Component Connector End Views
Door Lock/Window Switch - Driver X1 (A31/AU3)
Door Lock/Window Switch - Driver X2 (A31/AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Page 11761
Door Lock/Window Switch - Passenger (A31/AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Page 11762
Window Switch - Left Rear (Crew Cab with A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Page 11763
Window Switch - Right Rear (Crew Cab with A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Page 11764
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side
Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Left
Side
Front Side Door Window Switch Replacement - Left Side
Removal Procedure
1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the front
of the switch plate up to disengage clip. 3. Remove the switch plate out of the door trim panel
opening.
4. Disconnect the electrical connectors (3, 4) from the switches (2, 5). 5. Remove the switch plate
assembly (1) from the vehicle. 6. If replacing only the switches, remove the switches from the plate.
7. If replacing only the switch plate, retain the switches for transfer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11767
Installation Procedure
1. Install the switches (2, 5) to the switch plate (1). 2. Connect the electrical connectors (3, 4) to the
switches (2, 5).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the switch plate assembly to the door trim panel with the 2 screws and tighten to 2 Nm (18
lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11768
Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Right
Side
Front Side Door Window Switch Replacement - Right Side
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11769
Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement
Rear Side Door Window Switch Replacement
Removal Procedure
1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the switch
plate up and out of the door trim panel.
3. Disconnect the electrical connectors from the switch module. 4. Remove the switch plate
assembly from the vehicle. 5. If replacing only the switch module, remove the module from the
switch plate. 6. If replacing only the switch plate, retain the switch module for transfer.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11770
1. Install the switch module to the switch plate. 2. Connect the electrical connector to the switch
module.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the rear switch plate assembly to the door trim panel with the 2 screws and tighten to 2
Nm (18 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair
Front Door Window Motor: Service and Repair
Front Side Door Window Regulator Motor Replacement
Removal Procedure
Warning
Do not attempt to service the regulator motor without releasing the counterbalance spring tension.
The regulator lift arm is under tension from the counterbalance spring and can cause personal
injury if the motor is removed from the regulator.
1. Remove the front door window regulator. Refer to Front Side Door Window Regulator
Replacement (See: Window Regulator/Front Door
Window Regulator/Service and Repair/Front Side Door Window Regulator Replacement).
2. Drill a hole (1) through the window regulator bracket and lift arm. 3. Install a nut and bolt through
the hole (1) to secure the lift arm while the motor is removed.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair > Page 11776
4. Remove the bolts retaining the front window regulator motor to the regulator bracket. 5. Remove
the front window regulator motor from the regulator.
Installation Procedure
1. Install the front window regulator motor to the regulator.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the bolts retaining the front window regulator motor to the regulator bracket. Tighten the
front window regulator motor bolts to 4.5 Nm (40
lb in).
3. Remove the nut and bolt securing the lift arm to the regulator bracket. 4. Install the front window
regulator to the front door. Refer to Rear Side Door Window Regulator Replacement (See: Window
Regulator/Rear
Door Window Regulator/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Service and Repair
Rear Door Window Motor: Service and Repair
Rear Side Door Window Regulator Motor Replacement
Removal Procedure
1. Remove the rear door window regulator. Refer to Rear Side Door Window Regulator
Replacement (See: Window Regulator/Rear Door Window
Regulator/Service and Repair).
2. Remove the bolts retaining the rear window regulator motor to the regulator bracket. 3. Remove
the rear window regulator motor from the regulator.
Installation Procedure
1. Install the rear window regulator motor to the regulator.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Service and Repair > Page 11780
2. Install the bolts retaining the rear window regulator motor to the regulator bracket. Tighten the
rear window regulator motor bolts to 4.5 Nm (40 lb
in).
3. Install the rear door window regulator. Refer to Rear Side Door Window Regulator Replacement
(See: Window Regulator/Rear Door Window
Regulator/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Harness Routing Views
Power Window Switch: Locations Harness Routing Views
Harness Routing Views
Driver Door Harness Routing
1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside
Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body
Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver
Front Passenger Door Harness Routing
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Harness Routing Views > Page 11785
1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front
Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body
Harness) 9 - X210 (Body Harness to Front Passenger Door Harness)
Right Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Harness Routing Views > Page 11786
1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock
Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door
Harness)
Left Rear Door Harness Routing (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Harness Routing Views > Page 11787
1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness
to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Harness Routing Views > Page 11788
Power Window Switch: Locations Door Component Views
Door Component Views
Driver Door Components
1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker
- Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch
(DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF)
Front Passenger Door Components
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Harness Routing Views > Page 11789
1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door
Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210
Left Rear Door Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Harness Routing Views > Page 11790
1 - Speaker - Left Rear 2 - Window Switch - Left Rear (A31) 3 - X316 4 - Window Motor - Left Rear
(A31) 5 - Door Lock Actuator - Left Rear (AU3)
Right Rear Door Components (Crew Cab)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Harness Routing Views > Page 11791
1 - Window Switch - Right Rear (A31) 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right
Rear (AU3) 4 - Window Motor - Right Rear (A31) 5 - X317
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Page 11792
Power Window Switch: Diagrams
Component Connector End Views
Door Lock/Window Switch - Driver X1 (A31/AU3)
Door Lock/Window Switch - Driver X2 (A31/AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Page 11793
Door Lock/Window Switch - Passenger (A31/AU3)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Page 11794
Window Switch - Left Rear (Crew Cab with A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Page 11795
Window Switch - Right Rear (Crew Cab with A31)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Page 11796
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Service and Repair > Front Side Door Window Switch Replacement - Left Side
Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Left
Side
Front Side Door Window Switch Replacement - Left Side
Removal Procedure
1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the front
of the switch plate up to disengage clip. 3. Remove the switch plate out of the door trim panel
opening.
4. Disconnect the electrical connectors (3, 4) from the switches (2, 5). 5. Remove the switch plate
assembly (1) from the vehicle. 6. If replacing only the switches, remove the switches from the plate.
7. If replacing only the switch plate, retain the switches for transfer.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11799
Installation Procedure
1. Install the switches (2, 5) to the switch plate (1). 2. Connect the electrical connectors (3, 4) to the
switches (2, 5).
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the switch plate assembly to the door trim panel with the 2 screws and tighten to 2 Nm (18
lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11800
Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Right
Side
Front Side Door Window Switch Replacement - Right Side
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11801
Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement
Rear Side Door Window Switch Replacement
Removal Procedure
1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the switch
plate up and out of the door trim panel.
3. Disconnect the electrical connectors from the switch module. 4. Remove the switch plate
assembly from the vehicle. 5. If replacing only the switch module, remove the module from the
switch plate. 6. If replacing only the switch plate, retain the switch module for transfer.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11802
1. Install the switch module to the switch plate. 2. Connect the electrical connector to the switch
module.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the rear switch plate assembly to the door trim panel with the 2 screws and tighten to 2
Nm (18 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information
Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information
INFORMATION
Bulletin No.: 03-08-48-006H
Date: April 11, 2011
Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab
Models:
2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3
2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear
Window Defroster - RPO C49
Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate
Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories).
Repair Suggestions
Soldering Defroster Contact Tabs
In many cases the terminal tab will still be in the connector when you examine the vehicle. For
Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass),
always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector
(P/N 12034110). For all other vehicles, reconnect the original defroster tab.
In most applications it is preferable to create a new solder connection to reattach a separated rear
defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is
equal to, or stronger than, the original. The generic procedure below is not very time intensive, but
does include minor preparation work to create a good bonding surface. Be sure to follow each of
the steps, as combined they will produce the strongest bond possible. Please consider the
following before attempting the repair:
- Soldering introduces significant heat to the glass window of the vehicle. When performing the
re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and
have the solder in your other hand, ready to go, the moment you have enough heat to melt the
solder.
- If it is winter, bring the vehicle into the service garage and remove any snow from the back
window area. Allow time for the glass to warm to the temperature inside the building. Soldering
creates a "hot spot" in the glass. DO NOT solder on cold glass.
Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass
breakage. ALWAYS wear safety glasses when performing this repair!
- You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with
conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar,
making a strong and lasting repair.
- Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this
repair. Placing a shop towel under the soldering area is sufficient protection.
Soldering Procedure
1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a
new connector to the feed wire. The proper
connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5.
- Insert Delphi pick 12094430 to depress the locking tab on the terminal.
- Insert Delphi pick 12094429 to release the secondary lock tab.
Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with
moveable glass.
2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly
seated connector may cause excessive resistance
and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical
connector tab to the defroster tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 11812
3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size
utility models) and the defroster buss bar with fine
grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder,
but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close
up of a properly prepared surface.
Tip You may want to mask the glass around the contact area with tape. This is easy to do and will
allow you to safely prepare the contact surface without the risk of scratching the glass or the black
painted shading.
Important Most rear glass has a black painted masking around the edge of the glass. When
cleaning up the connection surface, be very careful not to damage the surface of the black shading
or the surface of the glass.
4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to
remove any residual oil or dirt.
Important
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 11813
You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with
conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is
available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for
this repair.
5. For this step, it is permitted that two technicians be used if required. Heat the new connector on
the surface of the buss bar that is to be soldered.
Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep
the solder ready and begin flowing out the solder as soon as the melting temperature has been
reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the
solder around the new contacts base. In this manner, as the melting point of the solder is reached,
a layer is deposited on the bottom side of the contact.
Important Try to align the new contact so that it is positioned with the same orientation as the
original contact.
6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the
performance of the bond; however, while it is unlikely
that customers may refer to the appearance of the rear window defroster and its components as a
positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor
cosmetic application.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Parts Information
Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada,
1-800-563-1717).
Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at
1-800-843-7422.
All other parts can be ordered through GMSPO or SSPO.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 11814
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr >
11 > A/C - Window Defroster Contact/Tab Repair Information
Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair
Information
INFORMATION
Bulletin No.: 03-08-48-006H
Date: April 11, 2011
Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab
Models:
2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3
2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear
Window Defroster - RPO C49
Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate
Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories).
Repair Suggestions
Soldering Defroster Contact Tabs
In many cases the terminal tab will still be in the connector when you examine the vehicle. For
Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass),
always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector
(P/N 12034110). For all other vehicles, reconnect the original defroster tab.
In most applications it is preferable to create a new solder connection to reattach a separated rear
defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is
equal to, or stronger than, the original. The generic procedure below is not very time intensive, but
does include minor preparation work to create a good bonding surface. Be sure to follow each of
the steps, as combined they will produce the strongest bond possible. Please consider the
following before attempting the repair:
- Soldering introduces significant heat to the glass window of the vehicle. When performing the
re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and
have the solder in your other hand, ready to go, the moment you have enough heat to melt the
solder.
- If it is winter, bring the vehicle into the service garage and remove any snow from the back
window area. Allow time for the glass to warm to the temperature inside the building. Soldering
creates a "hot spot" in the glass. DO NOT solder on cold glass.
Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass
breakage. ALWAYS wear safety glasses when performing this repair!
- You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with
conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar,
making a strong and lasting repair.
- Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this
repair. Placing a shop towel under the soldering area is sufficient protection.
Soldering Procedure
1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a
new connector to the feed wire. The proper
connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5.
- Insert Delphi pick 12094430 to depress the locking tab on the terminal.
- Insert Delphi pick 12094429 to release the secondary lock tab.
Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with
moveable glass.
2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly
seated connector may cause excessive resistance
and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical
connector tab to the defroster tab.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr >
11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11820
3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size
utility models) and the defroster buss bar with fine
grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder,
but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close
up of a properly prepared surface.
Tip You may want to mask the glass around the contact area with tape. This is easy to do and will
allow you to safely prepare the contact surface without the risk of scratching the glass or the black
painted shading.
Important Most rear glass has a black painted masking around the edge of the glass. When
cleaning up the connection surface, be very careful not to damage the surface of the black shading
or the surface of the glass.
4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to
remove any residual oil or dirt.
Important
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr >
11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11821
You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with
conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is
available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for
this repair.
5. For this step, it is permitted that two technicians be used if required. Heat the new connector on
the surface of the buss bar that is to be soldered.
Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep
the solder ready and begin flowing out the solder as soon as the melting temperature has been
reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the
solder around the new contacts base. In this manner, as the melting point of the solder is reached,
a layer is deposited on the bottom side of the contact.
Important Try to align the new contact so that it is positioned with the same orientation as the
original contact.
6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the
performance of the bond; however, while it is unlikely
that customers may refer to the appearance of the rear window defroster and its components as a
positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor
cosmetic application.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Parts Information
Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada,
1-800-563-1717).
Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at
1-800-843-7422.
All other parts can be ordered through GMSPO or SSPO.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr >
11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11822
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep
> 10 > Body - Vehicle Glass Distortion Information
Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10
> Body - Vehicle Glass Distortion Information
Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass >
Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information
Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion
Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Customer Interest: > 09-08-64-013A > May > 09 > Body - Front Door Glass
Inoperative/Binding/Rattling
Front Door Window Glass: Customer Interest Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Customer Interest: > 09-08-64-013A > May > 09 > Body - Front Door Glass
Inoperative/Binding/Rattling > Page 11844
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Customer Interest: > 09-08-64-013A > May > 09 > Body - Front Door Glass
Inoperative/Binding/Rattling > Page 11845
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 00-08-48-005D >
Sep > 10 > Body - Vehicle Glass Distortion Information
Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion
Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 06-08-64-001B >
Oct > 09 > Body - Side Window Chipping Information
Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping
Information
INFORMATION
Bulletin No.: 06-08-64-001B
Date: October 20, 2009
Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock
Box
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add vehicles and model years and to include all types of
door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body &
Accessories).
- In several warranty parts review cases, side door window glass was observed with a chip or chips
on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box
on the front side door window glass.
- A random selection of side door glass returns will be conducted to confirm adherence. If a side
door glass is discovered with a chip or chips in the location previously described, the side door
glass will be returned to the dealership for debit.
Example of Side Door Glass
- DO NOT place a vehicle key lock box on a side door window glass.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 06-08-64-001B >
Oct > 09 > Body - Side Window Chipping Information > Page 11855
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 09-08-64-013A >
May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling
Front Door Window Glass: All Technical Service Bulletins Body - Front Door Glass
Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 09-08-64-013A >
May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11860
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 09-08-64-013A >
May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11861
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 00-08-48-005D >
Sep > 10 > Body - Vehicle Glass Distortion Information
Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion
Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct
> 09 > Body - Side Window Chipping Information
Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping
Information
INFORMATION
Bulletin No.: 06-08-64-001B
Date: October 20, 2009
Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock
Box
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add vehicles and model years and to include all types of
door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body &
Accessories).
- In several warranty parts review cases, side door window glass was observed with a chip or chips
on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box
on the front side door window glass.
- A random selection of side door glass returns will be conducted to confirm adherence. If a side
door glass is discovered with a chip or chips in the location previously described, the side door
glass will be returned to the dealership for debit.
Example of Side Door Glass
- DO NOT place a vehicle key lock box on a side door window glass.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct
> 09 > Body - Side Window Chipping Information > Page 11871
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11872
Front Door Window Glass: By Symptom
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11873
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11874
Disclaimer
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11875
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11876
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11877
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11878
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11879
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11880
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Page 11881
Front Door Window Glass: Service and Repair
Front Side Door Window Replacement
Removal Procedure
1. Position the front door window approximately halfway down. 2. Remove the front door trim panel.
Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair).
3. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement
(See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair).
4. Remove the front door outer belt sealing strip. Refer to Front Side Door Window Belt Outer
Sealing Strip Replacement (See: Service and
Repair/Front Side Door Window Belt Outer Sealing Strip Replacement).
5. Remove the bolts retaining the front door window to the window regulator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Page 11882
6. Lift the window off of the window regulator. 7. Rotate the rear of the window upwards,
disengaging the window from the window run channel. 8. Remove the window from between the
inner and outer door panels.
Installation Procedure
1. Install the front door window into the front door between the inner and outer door panels. 2.
Rotate the rear of the window down, positioning the window into the window run channels. 3. Lower
the window down onto the window regulator.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
4. Install the bolts retaining the front door window to the window regulator. Tighten the front window
bolts to 9 Nm (80 lb in). 5. Install the front door outer belt sealing strip. Refer to Front Side Door
Window Belt Outer Sealing Strip Replacement (See: Service and
Repair/Front Side Door Window Belt Outer Sealing Strip Replacement).
6. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement
(See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Page 11883
7. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body
and Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information
Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair
Rear Door Window Glass: Service and Repair
Rear Side Door Window Replacement
Removal Procedure
1. Position the rear door window in the full up position. 2. Remove the rear door trim panel. Refer to
Rear Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear
Door/Rear Door Panel/Service and Repair).
3. Remove the rear inside door handle. Refer to Rear Side Door Inside Handle Replacement (See:
Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Rear Door Handle/Rear Door Interior Handle/Service and Repair).
4. Remove the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See:
Accessories and Optional Equipment/Radio, Stereo,
and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement).
5. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement
(See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair).
6. Remove the rear window run channel. Refer to Rear Side Door Window Channel Replacement
(See: Service and Repair/Rear Side Door Window
Channel Replacement).
7. Lower the rear door window in the full down position.
8. Remove the bolts retaining the rear door window to the window regulator. 9. Lift the rear window
off the regulator. Carefully lower the window down into the door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair > Page 11891
10. Remove the window from the door by sliding the window out between the inner panel (1) and
the upper window channel (2).
Installation Procedure
1. Install the rear door window to the rear door by inserting the front edge of the window into the
window channel (3), and sliding the rear of the
window down between the upper window channel (2) and the inner panel (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair > Page 11892
2. Position the rear door window onto the window regulator.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the bolts retaining the rear door window to the window regulator. Tighten the rear window
bolts to 9 Nm (80 lb in). 4. Raise the window to the full up position. 5. Install the rear door window
run channel. Refer to Rear Side Door Window Channel Replacement (See: Service and
Repair/Rear Side Door
Window Channel Replacement).
6. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See:
Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair).
7. Install the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See:
Accessories and Optional Equipment/Radio, Stereo, and
Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement).
8. Install the rear door inside handle. Refer to Rear Side Door Inside Handle Replacement (See:
Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Rear Door Handle/Rear Door Interior Handle/Service and Repair).
9. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Body
and Frame/Doors, Hood and Trunk/Doors/Rear
Door/Rear Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 09-08-64-013A >
May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling
Front Door Window Regulator: Customer Interest Body - Front Door Glass
Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 09-08-64-013A >
May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11902
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 09-08-64-013A >
May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11903
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: >
09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling
Front Door Window Regulator: All Technical Service Bulletins Body - Front Door Glass
Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: >
09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11909
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: >
09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11910
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page
11911
Front Door Window Regulator: By Symptom
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page
11912
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page
11913
Disclaimer
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page
11914
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page
11915
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page
11916
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page
11917
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 09-08-64-013A Date: 090511
Body - Front Door Glass Inoperative/Binding/Rattling
TECHNICAL
Bulletin No.: 09-08-64-013A
Date: May 11, 2009
Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten
Window Regulator Fasteners to Specification)
Models:
2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013
(Section 08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment that the driver or passenger side door glass is inoperative, has a
binding condition or a rattling noise.
Cause
This condition may be caused by the side door glass window regulator mounting bolts loosening.
Correction
Important Do not replace the door window regulator.
Use the following procedure to correct the condition.
1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water
Deflector Replacement in SI.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page
11918
3. Partially lower the side door glass on the affected door to relieve tension on the door glass
regulator and to expose the bolts retaining the front
door window to the window regulator.
Important Do not remove all of the window regulator bolts at the same time because the regulator
may fall into the door cavity, causing damage to the inner door components.
4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the
bolts and nuts one at a time and apply GM Medium
Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in
the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the
procedure to the remaining nuts and bolts one at a time.
5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one
at a time and apply GM Medium Strength
Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the
product information. Reinstall the bolts.
6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the
front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8.
Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel
Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been
corrected.
Parts Information
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page
11919
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Service and Repair > Door Window Regulator Handle Replacement
Front Door Window Regulator: Service and Repair Door Window Regulator Handle Replacement
Door Window Regulator Handle Replacement
Tools Required
J 9886-01 Door Handle Clip Remover
Removal Procedure
1. Raise the window to the full up position.
2. Remove the window regulator handle from the door by inserting tool J 9886-01 between the
handle and the white plastic washer. 3. Align the J 9886-01 with the handle. 4. Push the J 9886-01
in order to disengage the clip. 5. Pull the handle from the door.
6. Remove the window regulator handle from the door. 7. Remove the bearing plate from the door.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 11922
Installation Procedure
1. Ensure that the window is in the full up position. 2. Install the white plastic washer to the
regulator shaft. 3. Install the retaining clip to the handle.
4. Install the window regulator handle to the door with the handle forward at about a 50 degree
angle. 5. Push on the handle until the clip engages on the shaft.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 11923
Front Door Window Regulator: Service and Repair Front Side Door Window Regulator
Replacement
Front Side Door Window Regulator Replacement
Power window regulator (A31) shown, manual window regulator (without A31) similar.
Removal Procedure
1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair).
2. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement
(See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair).
3. Remove the bolts retaining the front door window to the window regulator. 4. Remove the front
door window. Refer to Front Side Door Window Replacement (See: Window Glass/Front Door
Window Glass/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 11924
5. Disconnect the electrical connector from the window regulator motor, if equipped with A31. 6.
Loosen the bolts (1) retaining the window regulator to the inner panel at the keyhole slot locations.
7. Remove the remaining fasteners retaining the window regulator to the inner panel. 8. Remove
the window regulator from the door by lifting the regulator up, and out of the keyhole slots, and
removing the regulator out through the
access hole.
Installation Procedure
1. Install the front door window regulator into the front door through the access hole.
2. Position the window regulator to the inner panel by sliding the regulator bolts (1) into the keyhole
slots in the inner panel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the fastener retaining the front door window regulator to the door. Tighten the front
window regulator fasteners to 9 Nm (80 lb in). 4. Connect the electrical connector to the window
regulator motor, if equipped with A31.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 11925
5. Install the front door window. Refer to Front Side Door Window Replacement (See: Window
Glass/Front Door Window Glass/Service and
Repair).
6. Install the bolts retaining the window to the window regulator. Tighten the front door window bolts
to 9 Nm (80 lb in). 7. Install the front door water deflector. Refer to Front Side Door Water Deflector
Replacement (See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair).
8. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body
and Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator >
System Information > Service and Repair
Rear Door Window Regulator: Service and Repair
Rear Side Door Window Regulator Replacement
Manual window regulator (without A31) shown, power regulator (A31) similar.
Removal Procedure
1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Body
and Frame/Doors, Hood and Trunk/Doors/Rear
Door/Rear Door Panel/Service and Repair).
2. Remove the rear inside door handle. Refer to Rear Side Door Inside Handle Replacement (See:
Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Rear Door Handle/Rear Door Interior Handle/Service and Repair).
3. Remove the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See:
Accessories and Optional Equipment/Radio, Stereo,
and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement).
4. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement
(See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair).
5. Remove the bolts retaining the rear window to the window regulator. 6. Raise and support the
rear door window.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator >
System Information > Service and Repair > Page 11929
7. Disconnect the electrical connector from the window regulator motor, if equipped with A31. 8.
Loosen the bolts retaining the window regulator (1) to the inner door at the keyhole slot (2)
locations. 9. Remove the bolts retaining the window regulator to the inner panel.
10. Remove the window regulator (1) by lifting the regulator up, and out of the keyhole slots (2) in
the inner panel, and removing the regulator out
through the access hole.
Installation Procedure
1. Install the rear door window regulator (1) into the rear door through the access hole. 2. Position
the rear door window regulator to the inner panel by inserting the regulator bolts to the keyhole
slots (2) on the inner panel.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
3. Install the bolts retaining the rear door window regulator to the inner panel. Tighten the rear
window regulator bolts to 9 Nm (80 lb in). 4. Connect the electrical connector to the window
regulator motor, if equipped with A31.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator >
System Information > Service and Repair > Page 11930
5. Remove the window support and lower the window onto the window regulator carrier plate. 6.
Install the bolts retaining the window to the window regulator. Tighten the rear window bolts to 9
Nm (80 lb in). 7. Install the rear door water deflector. Refer to Rear Side Door Water Deflector
Replacement (See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair).
8. Install the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See:
Accessories and Optional Equipment/Radio, Stereo, and
Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement).
9. Install the rear door inside handle. Refer to Rear Side Door Inside Handle Replacement (See:
Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Rear Door Handle/Rear Door Interior Handle/Service and Repair).
10. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Body
and Frame/Doors, Hood and Trunk/Doors/Rear
Door/Rear Door Panel/Service and Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
Customer Interest: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter
Windshield: Customer Interest Body - Stain/Film On Windshield Glass Perimeter
TECHNICAL
Bulletin No.: 09-08-48-006
Date: September 18, 2009
Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass)
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER
H2, H3
Condition
Some customers may comment on a clear stain or film on the inside of the windshield glass. This
condition appears along the outer edges of the glass along the top, bottom or A-pillar areas.
Normal glass cleaning procedures will not remove the stain.
Cause
The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve
adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess
sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries,
it may appear to have etched the glass.
Correction
Note
A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less
satisfactory results.
Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be
necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of
the windshield glass.
After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth
and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm
water.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
Customer Interest: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter > Page 11939
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
Customer Interest: > 09-08-48-002A > Mar > 09 > Body - Marks/Stains on Windshield When Wet
Windshield: Customer Interest Body - Marks/Stains on Windshield When Wet
TECHNICAL
Bulletin No.: 09-08-48-002A
Date: March 19, 2009
Subject: Marks/Stains on Windshield When Wet (Clean Windshield)
Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior
HUMMER H2, H3
Supercede: This bulletin is being revised to update the models and model years. Please discard
Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories).
Condition
Some owners may comment that marks/stains appear on the windshield when the windshield is
wet.
Cause
This condition may be caused by contact between the windshield and the vacuum hoses or other
tools used in the assembly process. This contact may leave a residue that creates a water repellent
surface on the glass which, in wet conditions, appear as marks/stains on the surface.
Correction
Important
DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION.
To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's
directions for product use. Use only hand tools. DO NOT USE POWER TOOLS.
Parts Information
Eastwood Glass Polishing Compound
1-800-343-9353 (for overseas inquiries: +1-610-705-2200)
http://www.eastwoodco.com/
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance
Windshield: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance
INFORMATION
Bulletin No.: 06-08-43-003C
Date: February 21, 2011
Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance
Models:
2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard
Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories).
Wiper Concerns
Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged
wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending
on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are
some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to
avoid unnecessary replacements.
Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong
with the returned blades other than a build-up of dirt. Additionally, advise the customer to review
the information in their Owner Manual.
Inspection and Cleaning
Scheduled Maintenance
- Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or
contamination.
- Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are
not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber
elements.
Cleaning Procedure
Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct
contact with washer fluid.
Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades.
- Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid
or a mild detergent. You should see significant amounts of dirt being removed on the cloth.
- Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and
a buildup of car wash/wax treatments may additionally cause wiper streaking.
Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami*
(www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid
scratching the glass. Flush the surface and body panels completely.
Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest
Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use
foaming cleaner that quickly removes dirt and grime from glass surfaces.
Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the
window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin
Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also
recommends using plain water to clean interior glass.
*"We believe this material to be reliable. There may be additional manufacturers of such material.
General Motors does not endorse, indicate any preference for or assume any responsibility for the
products or equipment from these firms or any such items which may be available from other
sources.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance
> Page 11949
Avoiding Wiper Damage
The following are major contributors to wiper damage. Some of these you can control and others
are environmental concerns.
- Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear
quickly and unevenly.
- Sand and salt used on roads for increasing winter traction and ice control will cause the wiper
blades to wear quicker. Areas with significant snowfall require more frequent blade replacements.
- Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not
flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas.
- Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a
frozen windshield can tear the rubber. Exercise caution when clearing ice and snow.
- Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the
ice, can dull, nick or tear the rubber blades.
- Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the
rubber and causing potential scratching of the windshield.
- Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To
remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the
frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition.
Note
GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid
additives. The variation in friction that results on the glass from the use of these products causes
wipers to chatter and have premature wear.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Windshield: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information
Windshield: All Technical Service Bulletins Body - Vehicle Glass Distortion Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Windshield: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass
Perimeter
Windshield: All Technical Service Bulletins Body - Stain/Film On Windshield Glass Perimeter
TECHNICAL
Bulletin No.: 09-08-48-006
Date: September 18, 2009
Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass)
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER
H2, H3
Condition
Some customers may comment on a clear stain or film on the inside of the windshield glass. This
condition appears along the outer edges of the glass along the top, bottom or A-pillar areas.
Normal glass cleaning procedures will not remove the stain.
Cause
The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve
adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess
sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries,
it may appear to have etched the glass.
Correction
Note
A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less
satisfactory results.
Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be
necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of
the windshield glass.
After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth
and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm
water.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Windshield: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass
Perimeter > Page 11958
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Windshield: > 09-08-48-002A > Mar > 09 > Body - Marks/Stains on Windshield When Wet
Windshield: All Technical Service Bulletins Body - Marks/Stains on Windshield When Wet
TECHNICAL
Bulletin No.: 09-08-48-002A
Date: March 19, 2009
Subject: Marks/Stains on Windshield When Wet (Clean Windshield)
Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior
HUMMER H2, H3
Supercede: This bulletin is being revised to update the models and model years. Please discard
Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories).
Condition
Some owners may comment that marks/stains appear on the windshield when the windshield is
wet.
Cause
This condition may be caused by contact between the windshield and the vacuum hoses or other
tools used in the assembly process. This contact may leave a residue that creates a water repellent
surface on the glass which, in wet conditions, appear as marks/stains on the surface.
Correction
Important
DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION.
To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's
directions for product use. Use only hand tools. DO NOT USE POWER TOOLS.
Parts Information
Eastwood Glass Polishing Compound
1-800-343-9353 (for overseas inquiries: +1-610-705-2200)
http://www.eastwoodco.com/
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance
Windshield: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance
INFORMATION
Bulletin No.: 06-08-43-003C
Date: February 21, 2011
Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance
Models:
2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard
Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories).
Wiper Concerns
Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged
wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending
on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are
some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to
avoid unnecessary replacements.
Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong
with the returned blades other than a build-up of dirt. Additionally, advise the customer to review
the information in their Owner Manual.
Inspection and Cleaning
Scheduled Maintenance
- Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or
contamination.
- Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are
not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber
elements.
Cleaning Procedure
Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct
contact with washer fluid.
Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades.
- Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid
or a mild detergent. You should see significant amounts of dirt being removed on the cloth.
- Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and
a buildup of car wash/wax treatments may additionally cause wiper streaking.
Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami*
(www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid
scratching the glass. Flush the surface and body panels completely.
Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest
Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use
foaming cleaner that quickly removes dirt and grime from glass surfaces.
Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the
window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin
Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also
recommends using plain water to clean interior glass.
*"We believe this material to be reliable. There may be additional manufacturers of such material.
General Motors does not endorse, indicate any preference for or assume any responsibility for the
products or equipment from these firms or any such items which may be available from other
sources.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance >
Page 11968
Avoiding Wiper Damage
The following are major contributors to wiper damage. Some of these you can control and others
are environmental concerns.
- Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear
quickly and unevenly.
- Sand and salt used on roads for increasing winter traction and ice control will cause the wiper
blades to wear quicker. Areas with significant snowfall require more frequent blade replacements.
- Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not
flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas.
- Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a
frozen windshield can tear the rubber. Exercise caution when clearing ice and snow.
- Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the
ice, can dull, nick or tear the rubber blades.
- Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the
rubber and causing potential scratching of the windshield.
- Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To
remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the
frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition.
Note
GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid
additives. The variation in friction that results on the glass from the use of these products causes
wipers to chatter and have premature wear.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Windshield: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information
Windshield: All Technical Service Bulletins Body - Vehicle Glass Distortion Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair >
Procedures
Windshield: Procedures
Windshield Glass Cleaning
Clean the windshield with windshield cleaner, GM P/N 1050011 (Canadian P/N 992727) or
equivalent. The cleaner should not harm the paint finish or scratch the glass. The glass is clean
when the water no longer beads, but sheets across the entire glass surface.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair >
Procedures > Page 11975
Windshield: Removal and Replacement
Windshield Replacement
Windshield Replacement
Special Tools
* J 24402-A Glass Sealant Remover (Cold Knife)
* J 39032 Stationary Glass Removal Tool
* Use a urethane adhesive systems which meet GM Specification GM 3651G
Removal Procedure
Note: Before cutting out a stationary window, apply a double layer of masking tape around the
perimeter of the painted surfaces and the interior trim.
1. Remove the fixed antenna mast. Refer to Fixed Antenna Mast Replacement (See: Accessories
and Optional Equipment/Antenna/Antenna
Mast/Service and Repair).
2. Open the hood. 3. Remove the window wiper arms. Refer to Windshield Wiper Arm
Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and Repair
).
4. Remove the cowl air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See: Body
and Frame/Cowl/Cowl Moulding / Trim/Service
and Repair).
5. Remove the inside rear view mirror. Refer to Inside Rearview Mirror Replacement (See: Body
and Frame/Mirrors/Service and Repair/Inside
Rearview Mirror Replacement).
6.
Pull back and position the auxiliary weatherstrip away from the pinch-weld flange.
Note: Both doors need to be opened.
7. Remove the windshield side reveal moldings. Refer to Windshield Side Reveal Molding
Replacement (See: Windshield Side Reveal Molding
Replacement). Warning: Refer to Glass and Sheet Metal Handling Warning (See: Body and
Frame/Service Precautions/Glass and Sheet Metal Handling Warning).
Warning
If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and
cause personal injury.
8. Cover to protect the following parts from broken glass:
* Upper dash pad
* Defroster outlets and A/C outlets
* Seats and carpeting
Note: The window lower supports (1) have molded in locks with an urethane adhesive strip (2) on
the back side. Once the window lower stop have been removed they must be replaced.
9. Remove the window lower supports (1) by using a flat-bladed tool, lightly prying upward in the
middle until it releases.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair >
Procedures > Page 11976
Note: Keep the cutting edge of the tool against the window.
10. This will allow the urethane adhesive to be separated from the window.
* Leave a base of urethane on the pinch-weld flange.
* The only suitable lubrication is clear water.
* Use J 24402-A , J 39032 or equivalent in order to remove the window.
11. Remove the bottom of the window from the urethane adhesive using a long utility knife or
similar tool. Keep the cutting edge of the utility knife
against the glass.
12. With the aid of an assistant (2) remove the window (1) from the vehicle.
Installation Procedure
1. Install a stationary window into the opening. Refer to Adhesive Installation of Stationary
Windows (See: Windows/Service and Repair/Adhesive
Installation of Stationary Windows).
2. Install the window side reveal moldings to the vehicle. Refer to Windshield Side Reveal Molding
Replacement (See: Windshield Side Reveal
Molding Replacement).
3. Reposition the auxiliary weatherstrip to the pinch-weld flange. 4. Install the antenna mast. Refer
to Fixed Antenna Mast Replacement (See: Accessories and Optional Equipment/Antenna/Antenna
Mast/Service
and Repair).
5. Install the cowl air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See: Body and
Frame/Cowl/Cowl Moulding / Trim/Service and
Repair).
6. Install the window wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper and
Washer Systems/Wiper Arm/Service and Repair). 7. Install the inside rear view mirror. Refer to
Inside Rearview Mirror Replacement (See: Body and Frame/Mirrors/Service and Repair/Inside
Rearview Mirror Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair >
Procedures > Page 11977
8. Close the hood. 9. Remove the double layer of masking tape around the perimeter of the painted
surfaces and the interior trim.
Windshield Side Reveal Molding Replacement
Windshield Side Reveal Molding Replacement
Removal Procedure
1. Open the doors 2. Partially remove the auxiliary weatherstrip (2). 3. Gently pry the reveal
molding (1) from the top working towards the air inlet panel. 4. Release the reveal molding from the
pinchweld flange. 5. Remove the reveal molding from the windshield pillar.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair >
Procedures > Page 11978
1. Install the reveal molding under the air inlet panel grille. 2. Align the reveal molding to the
pinchweld flange and to the top roof header. 3. Press the reveal molding (1) onto the pinchweld
flange. 4. Reposition the auxiliary weatherstrip (2). 5. Close the doors.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Relay > Component Information > Locations
Wiper Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information >
Service and Repair
Windshield Washer Hose: Service and Repair
Windshield Washer Hose Replacement
Removal Procedure
1. Raise and support the hood. 2. Remove the washer hose from the nozzles. Refer to Washer
Nozzle Replacement (See: Windshield Washer Spray Nozzle/Service and Repair).
3. Remove the hose from the air inlet panel. 4. Disconnect the hose (1) from the washer pump. 5.
Install a cap on the washer pump outlet in order to prevent excessive washer solvent loss. 6.
Remove the washer hose from the vehicle.
Installation Procedure
1. Position the new hose to the vehicle. 2. Remove the cap from the washer pump outlet and install
the new hose to the outlet of the pump.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information >
Service and Repair > Page 11987
3. Position the hose (1) to the air inlet panel (4). 4. Secure the hose to the air inlet grille panel. 5.
Connect the hose to the washer nozzles. Refer to Washer Nozzle Replacement (See: Windshield
Washer Spray Nozzle/Service and Repair). 6. Install the air inlet grille panel. Refer to Air Inlet Grille
Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and
Repair).
7. Top off the washer solvent container with washer solvent. 8. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Diagrams
Windshield Washer Pump: Diagrams
Component Connector End Views
Windshield Washer Fluid Pump
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Diagrams > Page 11991
Windshield Washer Pump: Service and Repair
Washer Pump Replacement (2nd Design)
Removal Procedure
1. Raise and support the hood. 2. Remove the washer solvent container. Refer to Windshield
Washer Solvent Container Replacement (See: Windshield Washer Reservoir/Service
and Repair).
3. Pull the top of the pump outward in order to release the pump from the container. 4. Using 2
flat-bladed tools under the pump, gently pry in opposite directions in order to release the pump
from the grommet. 5. Remove the washer pump (1) from the washer container. 6. Discard the
washer pump grommet.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Diagrams > Page 11992
1. Install the new washer pump (1) and grommet into the washer solvent container. 2. Use clean
washer solvent on the washer pump in order to aid in the installation of the new washer pump into
the grommet. 3. Apply downward pressure onto the pump in order to seat the pump to the
grommet. 4. Secure the top of the pump to the washer container. 5. Install the washer solvent
container. Refer to Windshield Washer Solvent Container Replacement (See: Windshield Washer
Reservoir/Service
and Repair).
6. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Service and Repair
Windshield Washer Reservoir: Service and Repair
Windshield Washer Solvent Container Replacement
Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine,
Cooling and Exhaust/Engine/Tune-up and Engine
Performance Checks/Air Cleaner Housing/Service and Repair) for the 2.8L (LK5) engine or Air
Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine
Performance Checks/Air Cleaner Housing/Service and Repair) for the 3.5L (L52) engine.
2. Remove the washer container to fender flange fasteners (1,2). 3. Remove the coolant reservoir
to wheelhouse fastener (3). 4. Slightly raise the container to access the electrical connection. 5.
Disconnect the electrical connector from the washer pump.
6. Remove the washer hose from the washer pump spout.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Service and Repair > Page 11996
7. Disengage the coolant recovery hose clips from the fender flange.
8. Remove the washer solvent container / coolant recovery reservoir (1) from the engine
compartment. 9. Drain the washer solvent and engine coolant into separate suitable containers.
10. Place the washer solvent container / coolant recovery reservoir onto a clean bench top. 11.
Remove the following component parts:
* Coolant container overflow hose (1)
* Coolant recovery reservoir cap (2)
* Windshield washer container cap (3)
* Coolant recovery to radiator hose (4)
* Windshield washer pump and grommet (5)
* Windshield washer container lower grommet (6)
12. Discard the washer solvent container / coolant recovery reservoir (7).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Service and Repair > Page 11997
Installation Procedure
1. Position a new washer solvent container / coolant recovery reservoir (7) on the bench top. 2.
Install the following component parts:
* Coolant container overflow hose (1)
* Coolant recovery reservoir cap (2)
* Windshield washer container cap (3)
* Coolant recovery to radiator hose (4)
* Windshield washer pump and a new grommet (5)
* Use clean washer solvent on the washer pump grommet to aid in the pump installation.
* Windshield washer container lower grommet (6)
3. Position the washer solvent container / coolant recovery reservoir (1) to the engine compartment
and fender flange. 4. Secure the washer hose to the washer pump spout. 5. Connect the electrical
connection to the washer pump.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Service and Repair > Page 11998
6. Route and engage the coolant recovery hose clips to the fender flange.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. Install the washer container to fender flange fasteners (1,2).
9 Nm (80 lb in)
8. Install the coolant recovery reservoir to wheelhouse fastener (3).
9 Nm (80 lb in)
9. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine,
Cooling and Exhaust/Engine/Tune-up and Engine
Performance Checks/Air Cleaner Housing/Service and Repair) for the 2.8L (LK5) engine or Air
Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine
Performance Checks/Air Cleaner Housing/Service and Repair) for the 3.5L (L52) engine.
10. Fill the washer solvent container with clean washer solvent. 11. Fill the coolant recovery
reservoir with new engine coolant per manufacturer's specification. 12. Test the washer system
and inspect for leaks. 13. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information
> Service and Repair
Windshield Washer Spray Nozzle: Service and Repair
Washer Nozzle Replacement
Removal Procedure
1. Raise and support the hood. 2. Remove both wiper arms. Refer to Windshield Wiper Arm
Replacement (See: Wiper Arm/Service and Repair). 3. Remove the fixed antenna mast. Refer to
Fixed Antenna Mast Replacement (See: Accessories and Optional Equipment/Antenna/Antenna
Mast/Service and Repair).
4. Remove the retainers (1, 3, 5) securing the air inlet panel grille (2) to the cowl panel. 5. Remove
the air inlet panel from around the hood hinges.
6. Roll the air inlet panel (4) forward. 7. Disconnect the hose from the washer nozzles (2, 3).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information
> Service and Repair > Page 12002
8. Press the tabs on the washer nozzles and remove the nozzles from the air inlet panel. 9.
Remove the washer nozzle from the air inlet panel.
Installation Procedure
1. Position the nozzles to the air inlet panel. 2. Press the nozzles into the panel in order to secure.
3. Install the hose to the nozzles (2, 3). 4. Secure the hose to the air inlet panel.
5. Ensure the foam washers (2) are secure to the retainers (1) prior to installing the air inlet grille
panel (3) to the cowl. 6. Position the air inlet panel around the hood hinges. 7. Secure the retainers
(1) to the cowl panel.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information
> Service and Repair > Page 12003
8. Install the retainers (5) to the air inlet panel (2) in order to secure. 9. Install the fixed antenna
mast. Refer to Fixed Antenna Mast Replacement (See: Accessories and Optional
Equipment/Antenna/Antenna
Mast/Service and Repair).
10. Install the wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper Arm/Service
and Repair). 11. Close the hood. 12. Test the washer spray pattern.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair
Wiper Arm: Service and Repair
Windshield Wiper Arm Replacement
Special Tools
J 39637 Wiper Arm Puller
Removal Procedure
1. Open the hood. 2. Remove the wiper arm nut cap(s) and discard.
3. Remove the wiper arm nut (2) from the wiper arm (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Page 12007
4. Using a J 39637 or equivalent, remove the wiper arm from the wiper arm pivot shaft if the wiper
arm fails to release from the pivot shaft with a
rocking motion.
5. Release the wiper arm blade (2) from the wiper arm (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Page 12008
6. Clean the pivot shaft knurls (1) with a soft wire brush.
Installation Procedure
1. Install the wiper arm blade (2) to the new wiper arm (1).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Page 12009
2. Lift the wiper blade off the windshield and install the wiper arm (1) to the wiper arm pivot shaft
(2). 3. Align the tip of the wiper blade with the round dot in the blackout area of the windshield.
4. For the passenger side blade (2), ensure the wiper blade tip is held in position to the alignment
dot (1) on the windshield.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Page 12010
5. For the driver side blade (2), ensure the wiper blade tip is held in position to the alignment dot (1)
on the windshield. 6. Holding the wiper blade to the windshield dot, install the wiper arm nut.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
7. Continue holding the wiper blade in position while tightening the nut.
Tighten the wiper arm nut to 33-38 Nm (24-28 lb ft).
8. Install new wiper arm nut covers. 9. Close the hood.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service
Bulletins > Glass/Body - Windshield Wiper Performance
Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance
INFORMATION
Bulletin No.: 06-08-43-003C
Date: February 21, 2011
Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance
Models:
2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard
Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories).
Wiper Concerns
Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged
wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending
on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are
some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to
avoid unnecessary replacements.
Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong
with the returned blades other than a build-up of dirt. Additionally, advise the customer to review
the information in their Owner Manual.
Inspection and Cleaning
Scheduled Maintenance
- Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or
contamination.
- Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are
not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber
elements.
Cleaning Procedure
Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct
contact with washer fluid.
Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades.
- Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid
or a mild detergent. You should see significant amounts of dirt being removed on the cloth.
- Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and
a buildup of car wash/wax treatments may additionally cause wiper streaking.
Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami*
(www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid
scratching the glass. Flush the surface and body panels completely.
Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest
Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use
foaming cleaner that quickly removes dirt and grime from glass surfaces.
Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the
window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin
Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also
recommends using plain water to clean interior glass.
*"We believe this material to be reliable. There may be additional manufacturers of such material.
General Motors does not endorse, indicate any preference for or assume any responsibility for the
products or equipment from these firms or any such items which may be available from other
sources.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service
Bulletins > Glass/Body - Windshield Wiper Performance > Page 12015
Avoiding Wiper Damage
The following are major contributors to wiper damage. Some of these you can control and others
are environmental concerns.
- Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear
quickly and unevenly.
- Sand and salt used on roads for increasing winter traction and ice control will cause the wiper
blades to wear quicker. Areas with significant snowfall require more frequent blade replacements.
- Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not
flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas.
- Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a
frozen windshield can tear the rubber. Exercise caution when clearing ice and snow.
- Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the
ice, can dull, nick or tear the rubber blades.
- Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the
rubber and causing potential scratching of the windshield.
- Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To
remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the
frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition.
Note
GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid
additives. The variation in friction that results on the glass from the use of these products causes
wipers to chatter and have premature wear.
Disclaimer
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair
> Procedures
Wiper Blade: Procedures
Wiper Blade Element Cleaning
Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full
strength washer solvent. Then rinse the blade assemblies with clear water.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair
> Procedures > Page 12018
Wiper Blade: Removal and Replacement
Windshield Wiper Blade Replacement
Windshield Wiper Blade Replacement
Removal Procedure
Important: Do not allow the wiper arm (1) to fall back and strike the windshield.
1. Lift the wiper arm and hold in the upright position. 2. Push upward the locking tab (3) of the wiper
blade clip and pull downward on the wiper arm blade (2). 3. Remove the wiper blade from the
inside radius of the wiper arm. 4. Bring the wiper arm out through the opening in the wiper blade.
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair
> Procedures > Page 12019
1. Position the wiper blade in the inside radius of the wiper arm hook. 2. Insert the hook of the
wiper arm through the opening in the wiper blade (2). 3. Pull upward until the locking tab (3) of the
pivot engages the slot in the hook. 4. Carefully lower the wiper arm and blade onto the windshield.
Wiper Blade Element Replacement
Wiper Blade Element Replacement
Removal Procedure
Important: Replace the wiper blade element if it is removed from the wiper blade.
1. Remove the wiper blade from the wiper arm. Refer to Windshield Wiper Blade Replacement
(See: Windshield Wiper Blade Replacement). 2. Disengage the bottom claws (2) of the wiper blade
(1) from the notches in the wiper blade element (3). 3. Pull the wiper blade element (3) out through
the wiper blade claws (2).
Installation Procedure
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair
> Procedures > Page 12020
Important: Keep the wiper blade claws in the rubber claw channel of the wiper blade element. Do
not allow the claws of the wiper blade to contact the metal spline of the wiper blade element.
1. Insert the open end of the wiper blade element (3) into the bottom claws of the wiper blade (2).
2. Guide the wiper blade element (3) through the wiper blade (1) claw sets. 3. Engage the bottom
claw (2) of the wiper blade (1) into the notches in wiper blade element (3). 4. Install the wiper blade
onto the wiper arm. Refer to Windshield Wiper Blade Replacement (See: Windshield Wiper Blade
Replacement).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and
Repair
Wiper Gear Box: Service and Repair
Windshield Wiper Transmission Replacement
Special Tools
* J 39232 Wiper Linkage Separator
* J 39529 Wiper Linkage Installer
Removal Procedure
1. Place the wiper arms in the 1/2 wipe position. 2. Turn the ignition key to the OFF position.
3. Remove the wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper Arm/Service
and Repair). 4. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See:
Body and Frame/Cowl/Cowl Moulding / Trim/Service and
Repair).
5. Disconnect the electrical connector (3) for the wiper motor. 6. Push the electrical harness
grommet (1) through the plenum panel into the cowl.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and
Repair > Page 12024
7. Remove the transmission fasteners (1, 4). Twist the transmission assembly in order to remove
the transmission assembly from the cowl. 8. Remove the transmission (3) from the vehicle through
the access openings in the top of the cowl.
Installation Procedure
1. Install the transmission (3) to the cowl area of the plenum. A slight twisting motion is needed in
order to install.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
2. Install the transmission mounting bolts (1, 4).
Tighten the wiper transmission mounting bolts to 9 Nm (81 lb in).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and
Repair > Page 12025
3. Position the electrical harness grommet to the plenum panel hole (5). 4. Pull the harness toward
the front of the vehicle in order to seat the harness grommet. 5. Connect the electrical connector. 6.
Install the connector position assurance tab (CPA) to the harness connector. 7. Cycle the wiper
system 1 time with the wiper motor switch. 8. Install the air inlet grille panel. Refer to Air Inlet Grille
Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and
Repair).
9. Install the wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper Arm/Service
and Repair).
10. Test the wiper system.
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations >
Harness Routing Views
Wiper Motor: Locations Harness Routing Views
Harness Routing Views
Body Harness Routing 1 of 3 (Regular Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor
(WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations >
Harness Routing Views > Page 12030
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor (C60)
Body Harness Routing 1 of 3 (Extended Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to
Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control
Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations >
Harness Routing Views > Page 12031
19 - A/C Refrigerant Pressure Sensor (C60)
Body Harness Routing 1 of 3 (Crew Cab)
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102
(Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body
Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body
Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed
Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid
Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60)
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations >
Harness Routing Views > Page 12032
Wiper Motor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left and Right Sides of Engine Compartment Components
1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper
Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102
8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations >
Harness Routing Views > Page 12033
17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure
Sensor
Rear of the Engine Compartment Components - 2 of 2
1 - Windshield Washer Fluid Pump 2 - Windshield Wiper Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page
12034
Wiper Motor: Diagrams
Component Connector End Views
Windshield Wiper Motor
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page
12035
Wiper Motor: Service and Repair
Windshield Wiper Motor Replacement
Special Tools
* J 39232 Wiper Linkage Separator
* J 39529 Wiper Linkage Installer
Removal Procedure
1. Place the wiper arms in the 1/2 wipe position. 2. Turn the ignition key to the OFF position.
3. Remove the wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper Arm/Service
and Repair). 4. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See:
Body and Frame/Cowl/Cowl Moulding / Trim/Service and
Repair).
5. Remove the wiper transmission (3). Refer to Windshield Wiper Transmission Replacement (See:
Wiper Gear Box/Service and Repair). 6. Using the J 39232 , separate the transmission link from
the wiper motor crank arm ball stud. 7. Remove the fasteners from the wiper motor to the frame
assembly. 8. Remove the wiper motor.
Installation Procedure
1. Install the wiper motor onto the wiper transmission frame.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener
Caution).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page
12036
2. Install the bolts in order to secure the motor to the frame.
Tighten the wiper motor mounting bolts to 9 Nm (81 lb in).
Note: Lubricate the socket with Multi-Purpose Lubricant, Superlube, GM P/N 12346241 (Canadian
P/N 10953474) or equivalent.
3. Install the transmission drive link socket onto the crank arm ball of the wiper motor using the J
39529 .
4. Install the wiper transmission (3) to the plenum. Refer to Windshield Wiper Transmission
Replacement (See: Wiper Gear Box/Service and
Repair).
Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations
Wiper Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label